Chevrolet - Cobalt - Workshop Manual - 2005 - 2005

Factory Workshop Manual Make Chevrolet Model Cobalt Engine and year L4-2.0L SC VIN P (2005) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 16 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 17 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 38 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 39 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 40 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 42 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 90 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 91 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 92 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 93 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 94 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 95 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 96 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 97 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 98 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 99 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 100 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 101 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 102 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 103 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 104 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 105 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 106 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 107 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 108 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 109 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 110 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 111 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 112 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 113 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 114 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 115 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 116 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 117 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 118 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 119 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 120 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 121 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 122 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 123 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 129 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 134 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 139 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 140 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 146 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 155 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 156 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 157 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 158 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 159 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 160 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 161 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 162 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 163 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 164 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 165 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 166 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 167 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 168 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 169 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 170 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 171 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 172 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 173 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 174 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 175 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 176 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 177 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 178 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 179 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 180 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 185 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 186 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 187 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 188 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 189 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 190 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 191 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 192 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 193 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 194 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 195 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 196 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 197 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 198 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 199 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 200 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 201 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 202 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 203 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 204 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 205 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 206 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 207 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 208 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 209 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 210 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 211 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 212 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 213 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 214 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 215 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 216 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 217 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 218 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 223 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 224 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 225 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 226 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 227 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 228 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 229 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 230 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 231 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 232 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 233 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 234 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 239 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 252 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 257 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 258 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 264 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 273 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 274 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 275 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 276 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 277 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 278 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 279 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 280 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 281 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 282 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 283 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 284 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 285 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 286 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 287 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 288 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 289 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 290 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 291 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 292 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 293 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 294 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 295 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 296 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 297 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 298 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 303 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 304 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 305 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 306 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 307 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 308 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 309 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 310 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 311 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 313 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 314 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 319 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 332 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 337 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 338 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 348 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 349 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 350 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 351 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 352 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 353 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 354 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 355 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 356 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 357 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 358 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 359 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 360 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 361 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 362 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 363 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 364 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 365 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 366 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 367 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 368 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 369 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 370 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 371 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 372 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 373 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 378 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 379 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 381 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 382 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 383 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 384 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 385 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 386 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 387 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 388 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 389 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 390 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 391 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 392 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 393 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 394 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 395 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 396 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 397 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 398 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 399 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 400 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 401 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 402 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 403 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 404 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 405 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 406 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 407 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 408 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 409 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 410 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 411 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 416 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 417 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 418 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 419 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 420 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 421 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 422 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 423 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 424 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 425 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 426 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 427 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 432 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations Rear Compartments And Shelf Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 444 Global Positioning System Module: Diagrams Vehicle Communication Interface Module (VCIM) C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 445 Vehicle Communication Interface Module (VCIM) C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 446 Vehicle Communication Interface Module (VCIM) C3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 447 Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 456 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 457 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 458 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 464 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 465 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 466 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement Seat Heater Control Module: Technical Service Bulletins Interior - Revised Seat Heater Module Replacement Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Front Heated Seat Control Module Replacement procedure in the Seats sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement > Page 472 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 473 Seat Heater Control Module: Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 474 Passenger Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 475 Seat Heater Control Module: Diagrams Heated Seat Module - Driver (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 476 Heated Seat Module - Passenger (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures The content of this article/image reflects the changes identified in TSB 05-08-50-011 Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 479 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 480 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: Customer Interest Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: All Technical Service Bulletins Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 494 Sunroof Control Module (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 504 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 505 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 511 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 512 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 513 Electronic Brake Control Module: Locations ABS Component Views 1 - Transmission Control Module (TCM) (MN5) 2 - LF Strut Tower 3 - Engine Control Module (ECM) (L61) 4 - Electronic Brake Control Module (EBCM) (JM4/JL9) 5 - Fuse Block - Underhood Bracket Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 514 Electronic Brake Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 515 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 516 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. If equipped with RPO LSJ, remove the throttle body air snorkel. 3. Clean the electronic brake control module (EBCM) (3) to brake pressure modulator valve (BPMV) (4) area of any accumulated dirt and foreign material. 4. Disconnect the electrical connector (1) from the EBCM (3). 5. Remove the 4 EBCM-to-BPMV retaining bolts (2). 6. Important: Do Not use a metal tool to pry the EBCM from the BPMV. Use care to ensure that the EBCM-to-BPMV mating surfaces are not scratched during EBCM removal. Separate the EBCM (3) from the BPMV (4) by carefully pulling apart. Installation Procedure 1. Clean the EBCM mating surface of the BPMV (4), with denatured alcohol, or equivalent. 2. Ensure that the EBCM (3) to BPMV (4) seal is fully seated in the groove on the EBCM (3). 3. Install the EBCM (3) to the BPMV (4). Use care when aligning the EBCM (3) to the BPMV electrical terminals (4). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 EBCM-to-BPMV retaining bolts (2). Tighten the bolts in a criss-cross pattern. ^ Tighten the bolts to 4.5 Nm (40 inch lbs.). 5. Connect the electrical connector (1) to the EBCM (3). 6. If equipped with RPO LSJ, install the throttle body air snorkel. 7. If a new EBCM was installed, the EBCM must be programmed. 8. Turn the ignition switch to the ON position. DO NOT start engine. 9. Perform the Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 525 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 526 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 532 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 533 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: All Technical Service Bulletins Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: Customer Interest Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 565 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 571 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Page 576 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 587 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 597 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 603 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 606 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 608 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 609 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 610 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 611 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 612 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 613 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 614 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 615 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 616 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 617 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 618 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 619 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 620 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 621 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 622 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 623 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 624 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 625 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 626 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 627 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 628 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 629 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 630 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 631 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 632 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 633 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 634 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 635 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 636 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 637 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 638 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 639 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 640 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 641 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 642 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 643 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 644 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 645 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 646 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 647 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 648 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 649 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 650 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 651 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 652 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 653 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 654 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 655 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 658 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 659 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 660 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 662 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 663 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 664 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 665 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 666 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 667 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 668 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 669 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 670 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 671 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 672 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 679 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 681 Body Control Module (BCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Body Control Module (BCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Body Control Module (BCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 684 Body Control Module (BCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Body Control Module (BCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Body Control Module (BCM) C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Body Control Module (BCM) C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Body Control Module (BCM) C3 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 689 Body Control Module (BCM) C4 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 690 Body Control Module (BCM) C4 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control module (BCM) has a bussed electrical center integrated into the housing. Body control relays and fuses are installed directly on the BCM, which simplifies wiring and junction blocks on the vehicle. The body control system consists of the BCM and its associated controls. Battery positive voltage is provided to the BCM from IBCM BATT 1 fuse and the IBCM BATT 2 fuse in the underhood fuse block. The module grounds are wired to ground G201, G203 and G305. The BCM is wired to the GMLAN High speed serial data buss, and the GMLAN Low speed serial data buss, as well as discrete input and output terminals to control the functions of the vehicle's body. Serial Data Gateway The body control module (BCM) in this vehicle functions as a translator between the High and Low speed GMLAN busses. The 2 communication protocols use the BCM to translate communicated serial data messages between the control modules over the 2 serial data busses. Power Mode Master This vehicles BCM functions as the Power Mode Master (PMM). Refer to Power Mode Description and Operation for a complete description of power mode functions. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The BCM functions include the following: A/C compressor request-Refer to Air Temperature Description and Operation in HVAC Systems Manual. - A/C cooling fan-Refer to Air Delivery Description and Operation in HVAC Systems - Manual. - Battery rundown protection (inadvertent power)-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Bulb check-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Chimes-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. Check gages - Door ajar warning - Headlamps ON - Key-in-ignition - Oil reset - Park brake warning - Seat belt not fastened - Turn signal ON - Door lock interface-Refer to Power Door Locks Description and Operation in Doors. - Electronic power steering (EPS)-Refer to Power Steering System Description and Operation in Power Steering System. - Engine coolant level sensing-Refer to Cooling System Description and Operation in Cooling System. - Exterior and interior lighting control-Refer to Exterior Lighting Systems Description and Operation in Lighting Systems. Automatic lighting control - Daytime running lamps (DRL) - Fog lamps - Park brake lights - Turn hazard lamps - Gage control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Horn interface-Refer to Horns System Description and Operation in Horns. - Instrument cluster indicator control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Interior lighting-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Key-in-ignition sensing-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. - Parking brake state sensing-Refer to Brake Warning System Description and Operation in Hydraulic Brakes. - Retained accessory power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Rear compartment interface-Refer to Power Door Locks Description and Operation in Doors. - Rear defogger-Refer to Rear Window Defogger Description and Operation in Heated Glass Element. - Remote function control-Refer to Keyless Entry System Description and Operation in Keyless Entry. - Seat belt use sensing-Refer to Seat Belt System Description and Operation in Seat Belts. - Content theft deterrent-Refer to Theft Systems Description and Operation in Theft Deterrent. - Vehicle theft deterrent-Refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Washer solvent level sensing-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. - Wiper/washer-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 693 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation for more information about the gateway. The powertrain control module (PCM) on this vehicle, uses a class 2 serial data buss. The class 2 buss is only used for diagnostics and the service programming system (SPS). During normal vehicle operations, there is no communications over the class 2 serial data buss. Normal vehicle operational messaging for the PCM is sent over the PCMs GMLAN high speed serial data buss. GMLAN HIGH SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. NOTE: a loss of serial data DTC does not represent a failure of the module that the code is set in. GMLAN LOW SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pules is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. CLASS 2 CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data circuit. Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7 volts nominal and inactive at ground potential. When the ignition switch is in RUN, and a scan tool is connected to the DLC, the powertrain control module (PCM) will start communicating diagnostic information over the class 2 serial data circuit. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Pin 1 GMLAN low speed communications terminal - Pin 2 Class 2 signal terminal - Pin 4 Scan tool power ground terminal - Pin 5 Common signal ground terminal - Pin 6 High speed GMLAN serial data bus (+) terminal - Pin 14 High speed GMLAN serial data bus (-) terminal - Pin 16 Scan tool power, battery positive voltage terminal CLASS 2 SERIAL DATA USAGE The class 2 serial data communications circuit on this vehicle is only used for powertrain control module (PCM) diagnostics and PCM service programming system (SPS) programming. SERIAL DATA REFERENCE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 694 The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 695 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION Power to many of this vehicle's circuits are controlled by the module that is designated the Power Mode Master (PMM). This vehicle's PMM is the Body Control Module (BCM). The PMM controls which power mode (Run, Accessory, Crank, Retained Accessory Power, or Off) is active. Serial Data Power Mode Master On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle, the PMM is the body control module (BCM). The PMM receives 3 discrete ignition switch signals to differentiate which power mode will be sent over the Serial Data circuits. The 3-wire Ignition Switch table illustrates the state of these inputs in correspondence to the ignition switch position. Relay Controlled Power Mode The body control module (BCM) uses the discrete ignition switch inputs Off/Run/Crank, Accessory, and ignition 1, to distinguish the correct power mode. The ignition 1 circuit is also routed to the Run/Crank relay for relay controlled power feeds during the appropriate power mode. The BCM, after determining the desired power mode, will activate the appropriate relays for that power mode. Run/Crank Relay The run/crank relay control circuit is connected to a constant ground and is switched by the ignition 1 circuit or the body control module (BCM). The BCM, will in lieu of the ignition switch position, activate the Run/Crank relay during a remote start event. The Run/Crank relay supplies a power signal to the following circuits, when the a Run or Crank power mode is selected: Automatic transmission shift indicator - Automatic transmission (A/T) - Switched power feeds to the BCM - Electronic brake control module (EBCM) - Electronic ignition module (spark control) - Electronic power steering module (EPS) - Fuel injectors - Powertrain control module (PCM) - Park neutral position (PNP) switch Accessory (ACC) Relay The adaptive cruise control (ACC) relay is energized when the Run or accessory power mode has been selected. The relay uses a Hot At All Times B+ power source derived from the underhood electrical center. The ACC relay is also energized by the body control module (BCM) to supply power during the retained accessory power (RAP) mode. The following devices are controlled by this relay: Inside rearview mirror - Heated seats - Power windows - Sunroof - Wiper washers switch Fail-Safe Operation Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the power mode master (PMM) fail to send a power mode message. The fail-safe plan covers those modules, using exclusively serial data control of power mode, as well as those modules with discrete ignition signal inputs. Serial Data Messages The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid power mode master (PMM) message until they can check for the engine run flag status on the serial data circuits. If the PMM fails, the modules monitor the serial data circuit for Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 696 the engine run flag serial data. If the engine run flag serial data is True, indicating that the engine is running, the modules fail-safe to RUN. In this state, the modules and their subsystems can support all operator requirements. If the engine run flag serial data is False, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Discrete Ignition Signals Those modules that have discrete ignition signal inputs, also remain in the state dictated by the last valid power mode master (PMM) message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, battery positive voltage, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 volts, the modules will fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. BCM Wake-Up/Sleep States The body control module (BCM) is able to control or perform all of the BCM functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system functions has stopped, and the BCM has become idle again. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors for these inputs during the sleep state, where the BCM is able to detect switch transitions that cause the BCM to wake-up when activated or deactivated. Multiple switch inputs are needed in order to sense both the insertion of the ignition key and the power mode requested. The BCM will enter a wake-up state, if any of the following wake-up inputs are detected: Activity on the serial data line - Detection of a battery disconnect and reconnect condition - Headlamps are ON. - Ignition is turned ON. - Key-in-ignition switch - Park lamps are ON. - RFA message The BCM will enter a sleep state when all of the following conditions exist: The ignition switch is OFF. - No activity exists on the serial data line. - No outputs are commanded. - No delay timers are actively counting. - No wake-up inputs are present. If all these conditions are met, the BCM will enter a low power or sleep condition. This condition indicates that the BCM, which is the power mode master (PMM) of the vehicle, has sent an OFF or OFF-ASLEEP message to the other systems on the serial data line. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 697 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The Radio uses an exclusive RAP message that can not be circumvented by any door but the drives door. The BCM then sends a serial data power mode message ending the RAP function. The radio is the only module that is controlled by the serial data circuits. RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) The body control module (BCM) keeps the accessory relay energized during all power modes, except Off-Awake and Crank. The devices powered by the accessory relay during the retained accessory power (RAP) power mode are the sunroof and windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 700 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Scan Tool Does Not Communicate with Low Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With Low Speed GMLAN Device - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 701 Steps 1-12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 702 Steps 13-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 703 Steps 1-12 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle serial data communications and the control modules operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by a module which acts as the power mode master (PMM) in order to determine the correct power mode. The module which is the PMM communicates the system power mode to all modules on the serial data lines. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 704 Steps 1-6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 705 Steps 7-14 The numbers below refer to the step numbers on the diagnostic table. 6. This step tests for battery voltage on the incorrect signal circuits. 7. This step tests for no battery voltage on the required signal circuits. 8. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 9. This step eliminates open circuits as the cause of the malfunction. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 706 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Accessory Relay Command: The scan tool displays the state of the accessory relay command. Battery Voltage Signal: The scan tool displays the vehicle voltage. Ignition Mode Switch: The scan tool displays the ignition switch voltage signal. This signal is derived from the ignition Off/Run/Crank circuit. Ignition Switch Accessory: The scan tool displays the state of the ignition switch accessory circuit. Ignition Switch Run/Crank: The scan tool displays the state of the ignition switch Run/Crank circuit. Key In Ignition Cylinder: The scan tool displays whether or not the key is in the ignition cylinder. Power Mode: The scan tool displays the vehicle power mode. Run Relay Command: The scan tool displays the state of the Run relay. Run Crank Relay Command: The scan tool displays the state of the Run Crank relay. Vehicle Control Systems Data BCM Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. A new body control module (BCM) must be programmed with the proper regular production option (RPO) configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. The Tech 2 software will automatically prompt you with the RPO available for the vehicle. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the Vehicle Control Systems in Computer/Integrating Systems menu on the scan tool to program the BCM. Select Module Replacement/Setup and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passkey 3 Programming Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passkey 3 Programming procedure. Perform the Passkey 3 Programming Procedure if any of the following components have been replaced: The BCM - The powertrain control module (PCM)Refer to Programming Theft Deterrent System Components in Theft Deterrent for the proper procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 709 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 713 Throttle Actuator Control (TAC) Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 722 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 728 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 733 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-05-25-001 > Jan > 05 > Engine Controls - False DTC U2108 Set Engine Control Module: All Technical Service Bulletins Engine Controls - False DTC U2108 Set Bulletin No.: 05-05-25-001 Date: January 04, 2005 INFORMATION Subject: Information on a Falsely Set DTC U2108 in Engine Control Module (ECM) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) with Non-ABS Brake System (RPO J41) Built Prior to February, 2005 Technicians may observe DTC U2108 (ECM Lost Communications With ABS/TCS Control System), current or in history, stored in the ECM when the vehicle is connected to the Tech 2(R). This DTC is associated with ABS equipped vehicles. Because the above vehicle is not equipped with ABS, this may cause confusion. The ECM may falsely set a DTC U2108 in cars not equipped with ABS due to a software condition. A DTC U2108 will NOT illuminate a SES/MIL light. A code clear will only momentarily clear this DTC and will return to a current state almost immediately. No repairs to the vehicle are necessary as a result of a DTC U2108. DO NOT REPLACE THE BCM OR ECM. If the SES/MIL light is illuminated with a DTC U2108 present, look for additional DTCs causing the condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 747 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-05-25-001 > Jan > 05 > Engine Controls - False DTC U2108 Set Engine Control Module: All Technical Service Bulletins Engine Controls - False DTC U2108 Set Bulletin No.: 05-05-25-001 Date: January 04, 2005 INFORMATION Subject: Information on a Falsely Set DTC U2108 in Engine Control Module (ECM) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) with Non-ABS Brake System (RPO J41) Built Prior to February, 2005 Technicians may observe DTC U2108 (ECM Lost Communications With ABS/TCS Control System), current or in history, stored in the ECM when the vehicle is connected to the Tech 2(R). This DTC is associated with ABS equipped vehicles. Because the above vehicle is not equipped with ABS, this may cause confusion. The ECM may falsely set a DTC U2108 in cars not equipped with ABS due to a software condition. A DTC U2108 will NOT illuminate a SES/MIL light. A code clear will only momentarily clear this DTC and will return to a current state almost immediately. No repairs to the vehicle are necessary as a result of a DTC U2108. DO NOT REPLACE THE BCM OR ECM. If the SES/MIL light is illuminated with a DTC U2108 present, look for additional DTCs causing the condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 756 Engine and Transmission Modules Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 762 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 768 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 769 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 771 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 772 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 773 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 774 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 775 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 776 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 777 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 778 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 779 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 780 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 781 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 782 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 783 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 784 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 785 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 786 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 787 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 788 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 789 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 790 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 791 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 792 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 793 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 794 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 795 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 796 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 797 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 798 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 799 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 800 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 801 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 802 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 803 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 804 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 805 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 806 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 807 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 808 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 809 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 812 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 815 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 816 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 817 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 819 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 820 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Powertrain Control Module (PCM) C3 (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 842 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCs) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 843 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The engine knock sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 844 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) is the control center for the throttle actuator control (TAC) system. The PCM determines the drivers intent and then calculates the appropriate throttle response. The PCM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 845 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. Disconnect the 3 powertrain control module (PCM) harness connectors from the PCM, noting proper orientation. 4. Use the retaining tab to release the PCM from the underhood junction block bracket. INSTALLATION PROCEDURE 1. Use the retaining tab to secure the PCM, when installing the PCM to the underhood junction block bracket. 2. Connect the PCM harness connectors to the PCM. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 860 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 861 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 863 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 864 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 865 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 866 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 867 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 868 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 869 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 870 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 871 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 872 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 873 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 874 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 875 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 876 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 877 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 878 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 879 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 880 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 881 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 882 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 883 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 884 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 885 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 886 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 887 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 888 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 889 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 890 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 891 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 892 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 893 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 894 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 895 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 896 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 897 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 898 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 899 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 900 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 908 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 909 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 910 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 911 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 912 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 920 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Ignition Coil/module 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 929 Ignition Coil/Module 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 930 Ignition Coil/module 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 931 Ignition Coil/Module 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 932 Ignition Control Module: Description and Operation IGNITION COIL/MODULE Each ignition coil/module has the following circuits: - An ignition voltage circuit - A ground - An ignition control (IC) circuit - A low reference circuit The PCM controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event. The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 942 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 943 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 949 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 950 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 951 Air Bag Control Module: Locations Seat Belt Pretensioners - Coupe Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 952 Seat Belt Pretensioners - Sedan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 960 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Air Bag Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 964 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 965 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 967 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 968 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 969 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 970 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 971 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 972 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 973 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 974 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 975 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 976 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 977 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 978 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 979 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 982 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 983 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 984 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 985 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 986 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 987 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 988 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 989 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 990 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 991 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 992 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 993 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 994 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 995 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 996 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 997 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 998 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 999 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1021 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1022 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1023 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1024 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1025 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1026 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1027 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1028 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1029 Air Bag Control Module: Connector Views Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1030 Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1031 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 1033 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the supplemental inflatable restraint (SIR) system. This SDM has 2 fused power inputs; one fuse is for the battery voltage and the other fuse is for the ignition voltage. The SDM uses vehicle battery voltage as its main power input. The SDM then uses the vehicles GMLAN Serial Data Communication line and the ignition voltage logic input for enabling or disabling the SIR deployment loops. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags or seat belt pretensioners. If the force of the impact is not sufficient to warrant inflator module deployment, the SDM may still deploy the seat belt pretensioners. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. As soon as 3 distinct deployment commands (representing different events) have been issued to any belt pretensioner, or the SDM commands any front and side air bag to deploy once, the SDM shall be considered to not be reusable. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 1034 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 1035 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System (PPS) Operation Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Steering Wheel and Column Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 1045 Steering Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 1046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 1047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 1063 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 1074 Door Lock Switch - Passenger (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 1075 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Outside Rearview Mirror Switch (With RPO Code DG7) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 1081 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 1085 Rear Compartment Lid Release Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1089 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1090 Seat Heater Switch: Diagrams Heated Seat Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 1091 Heated Seat Switch = Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 1094 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: Customer Interest Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 1103 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: All Technical Service Bulletins Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 1109 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 1110 Headliner Components (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 1111 Sunroof Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. INSTALLATION PROCEDURE 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 1114 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. Installation Procedure 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LR of the Engine Compartment LR of the Engine Compartment 1 - Brake Fluid Level Switch 2 - Windshield Wiper Motor 3 - LF Strut Tower 4 - Fuse Block Underhood Connectors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1119 Brake Fluid Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1123 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1124 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensors (JM4/JL9) Wheel Speed Sensors (JM4/JL9) 1 - Wheel Speed Sensor (WSS) - LF 2 - Wheel Speed Sensor (WSS) - RF 3 - Wheel Speed Sensor (WSS) - RR 4 - Wheel Speed Sensor (WSS) - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 1128 Wheel Speed Sensor: Diagrams Wheel Speed Sensor - LF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 1129 Wheel Speed Sensor - RF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 1130 Wheel Speed Sensor - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 1131 Wheel Speed Sensor - RR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1140 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1141 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1142 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1143 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1153 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1159 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1160 Brake Switch (Cruise Control): Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1161 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1162 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard.The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 1. The release switch (1) 2. The stop lamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1163 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the cruise control release switch. 2. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. Refer to Cruise Release Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1172 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1178 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Blower Motor Switch: Customer Interest A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 1198 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C Broken Blower Motor Control Knob Blower Motor Switch: All Technical Service Bulletins A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C Broken Blower Motor Control Knob > Page 1204 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1210 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1216 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Front Lower Left Of The Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1220 A/C Refrigerant Pressure Sensor (With RPO Code C67) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1221 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the pressure sensor. 3. Remove the pressure sensor from the compressor hose. 4. Remove and discard the seal. INSTALLATION PROCEDURE 1. Install a new seal in the pressure sensor. 2. Install the pressure sensor to the compressor hose. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the pressure sensor to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1222 3. Connect the pressure sensor electrical connector. 4. Lower the vehicle. 5. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 1227 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 1228 I/P Dimmer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 1229 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 1233 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 1234 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 1235 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: Customer Interest Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 1244 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 1250 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1251 Fuel Pump and Sender Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1252 Fuel Gauge Sender: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fill limit vent valve - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel pump - The fuel pressure regulator - The fuel strainer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1253 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED - SA9156E Fuel Tank Lock Ring Remover - J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank. 2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer. 3. Release the fuel pump module electrical harness from the retaining slot on the tank. 4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 5. Using the SA9156E, or J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1254 6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness. 7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank. 9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container. 10. Remove and discard the fuel pump module-to-fuel tank seal (1). IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1255 1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank. 3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly. 4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 1256 5. Using the SA9156E, or J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring. IMPORTANT: Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots. 6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor. 7. Secure the fuel pump module electrical harness into the retaining slot on the tank. 8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer. 9. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 1260 Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1264 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1265 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1270 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1271 Ambient Light Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1272 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Components (MPG) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1284 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 1290 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1291 Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1292 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1293 Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1294 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1295 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. With the brake pedal fully released, insert the stop lamp switch into the brake pedal bracket until the switch plunge is fully depressed into the barrel. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 3. Twist the switch clockwise until the travel stop has been reached. 4. The plunger should extend out of the barrel (1) of the switch approximately 1.0 mm (0.04 in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1296 5. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in) 6. Inspect the stop lamps for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1297 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. Remove the stop lamp switch by grasping the switch and turning it counterclockwise while pulling toward the front of the vehicle. 3. Disconnect the stop lamp switch electrical connector. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1298 1. Connect the stop lamp switch electrical connector. 2. Insert the stop lamp switch into the retainer. 3. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in). 4. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 1302 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1306 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1307 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1308 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1312 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1313 Fog Lamp Switch (With RPO Code T37) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1314 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1318 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1319 Hazard Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1320 Hazard Warning Switch: Service and Repair HAZARD WARNING SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1321 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Power Steering System Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1328 Turn Signal Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1329 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1330 Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Removal Procedure 1. Remove the steering column trim covers. 2. Disconnect the multifunction turn signal switch harness connector. 3. Depress the locking tabs and remove the multifunction turn signal switch from the steering column. Installation Procedure 1. Install the multifunction turn signal switch to the steering column. Ensure the locking tabs are snapped into place. 2. Connect the multifunction turn signal switch harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1331 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1337 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1338 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1419 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Top Left Side of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1423 Barometric Pressure Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1424 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor harness connector. 2. Remove the BARO sensor bracket and bolt. 3. Remove the BARO sensor (2). INSTALLATION PROCEDURE 1. Install the BARO sensor (2). 2. Install the BARO sensor bracket and bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the BARO sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1428 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1429 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1510 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1511 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1512 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 1516 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 1517 Clutch Pedal Position (CPP) Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1521 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1522 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1523 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1524 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1530 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1603 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1605 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1608 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The powertrain control module (PCM) sends the fuel level information via the GMLAN serial data circuit to the body control module (BCM). The BCM sends the GMLAN message to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 1612 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the fuel pump module assembly. 2. Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl. 3. Disconnect the fuel level sensor electrical connector from the pump module. 4. Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module. 5. Carefully slide the level sensor the rest of the way off of the pump module. INSTALLATION PROCEDURE 1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. 2. Secure the retaining tab (2) on the sensor into the slot on the pump module bowl. 3. Connect the fuel level sensor electrical connector to the pump module. 4. Install the fuel level sensor wiring harness to the molded-in tab (1) on the pump module bowl. 5. Install the fuel pump module assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1616 Fuel Tank Pressure (FTP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1617 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1618 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4. Carefully use the screwdrivers to lift and release the sensor from the fuel pump module. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1619 1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor grommet is fully seated to the pump module. 2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1623 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1624 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor harness connector. 2. Remove the IAT sensor bolt. 3. While twisting the IAT sensor (3), pull the sensor from the engine. INSTALLATION PROCEDURE 1. Press the IAT sensor (3) into the engine. 2. Install the IAT sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the IAT sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1645 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1646 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1647 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1648 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1649 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1650 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1704 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1705 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1709 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (TMAP) REMOVAL PROCEDURE 1. Disconnect the temperature manifold absolute pressure (TMAP) sensor harness connector. 2. Remove the TMAP sensor from the intake manifold. 3. Inspect the seal for damage. IMPORTANT: If the TMAP sensor seal is damaged, the TMAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the TMAP sensor into the intake manifold. IMPORTANT: Use the new TMAP sensor seal provided with the new TMAP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the TMAP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) > Page 1712 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (SCIP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (SCIP) REMOVAL PROCEDURE 1. Disconnect the supercharger inlet pressure (SCIP) sensor harness connector. 2. Remove the SCIP sensor (1) from the supercharger. 3. Inspect the seal for damage. IMPORTANT: If the SCIP sensor seal is damaged, the SCIP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the SCIP sensor (1) into the intake manifold. IMPORTANT: Use the new SCIP sensor seal provided with the new SCIP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the SCIP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Rear of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1719 HO2S 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) - 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 Heated Oxygen Sensor (HO2S) - 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 1 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor using J 39194-C. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 1800 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 1801 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 2 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 2 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel drive shaft heat shield. 3. Note the routing of the heated oxygen sensor (HO2S) electrical harness. 4. Disconnect the HO2S electrical connector (2), in the engine compartment. 5. Carefully bend the edge of the channel on the LH side of the exhaust heat shield outboard, just enough to release the HO2S electrical harness (1). 6. Using the J 39194 carefully remove the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. - Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 1802 7. Lower the HO2S electrical harness away from the underbody. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 24185279, or equivalent. 2. Carefully install the HO2S to the pipe. 3. Using the J 39194, or equivalent, tighten the HO2S. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten the HO2S to 41 N.m (30 lb ft). 4. Install the HO2S electrical harness into position as noted before removal. 5. Carefully bend the edge of the channel (1) on the LH side of the exhaust heat shield inboard, just enough to secure the HO2S electrical harness in the channel. IMPORTANT: Use care when securing the HO2S electrical harness into the channel on the exhaust heat shield, to not pinch the wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 1803 6. Connect the HO2S electrical connector (2). 7. Install the wheel drive shaft heat shield. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 1885 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 1886 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 1887 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 1888 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 1889 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed > Page 1894 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed Vehicle Speed Sensor: Service and Repair Getrag 5 Speed Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Pull up on the VSS in order to remove the VSS from the transaxle. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 1897 3. Install the VSS assembly. 4. Install the VSS retainer. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 12 Nm (8 ft. lbs.). 6. Connect the VSS connector to the VSS. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 1898 Vehicle Speed Sensor: Service and Repair MU3 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the left front wheel. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the retainer bolt. 4. Remove the retainer. 5. Remove the VSS. 6. Remove and discard the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid Saturn P/N 121019223. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 1899 3. Install the VSS retainer.Install the vehicle speed sensor (VSS) assembly. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS (2). 6. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 1900 Vehicle Speed Sensor: Service and Repair 4T40-E/4T45-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable from the battery negative terminal. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to the case. Installation Procedure 1. Clean and dry the vehicle speed sensor. 2. Notice: Install the vehicle speed sensor and the retaining bolt. ^ Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Remove the safety stands. 5. Lower the vehicle. 6. Connect the negative battery cable. ^ Tighten the terminal bolt to 15 Nm (11 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1905 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1906 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1950 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1951 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1952 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1953 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1954 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1955 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 1987 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1997 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1998 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1999 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2000 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2001 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2002 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2003 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2004 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2005 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2008 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2009 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2072 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2073 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2074 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2075 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2147 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2148 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2149 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2230 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2233 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2247 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2248 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2249 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 2258 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2268 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2269 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2270 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 2279 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2368 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2369 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Front End Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions Impact Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Impact Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2413 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2414 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2415 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2421 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2424 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2425 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2426 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 Impact Sensor: Connector Views Inflatable Restraint Side Impact Sensor - Left (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Inflatable Restraint Side Impact Sensor - Right (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2452 Inflatable Restraint Front End Discriminating Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor Impact Sensor: Description and Operation Front End Sensor INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on vehicles to supplement the supplemental inflatable restraint (SIR) system performance. The front end sensor is an electronic sensor and is not part of the deployment loops, but instead provides an input to the sensing and diagnostic module (SDM). The front end sensor can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor > Page 2455 Impact Sensor: Description and Operation Side Impact Sensor (SIS) INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 2458 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 2459 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 2460 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2464 Seat Belt Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information > Page 2469 Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 2474 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 2475 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 2484 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 2490 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Page 2491 Clutch Switch: Locations Manual Transmission Component Views Pedal Components Pedal Components 1 - Clutch Pedal Position (CCP) Switch (M86) 2 - Clutch Start Switch (M86) 3 - Stop Lamp Switch 4 - Cruise Control Cancel Switch (M86) 5 - Accelerator Pedal Position (APP) Sensor 6 - Floor Pan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 Clutch Switch: Diagrams M86 Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 > Page 2494 Clutch Start Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 > Page 2495 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Old Pedal Clutch Switch: Adjustments Old Pedal Clutch Pedal Position Switch Adjustment (Old Pedal) Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Remove the CPP switch (1) from the clutch pedal by twisting the CPP switch (1) counterclockwise. Installation Procedure 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly and twist the CPP switch (1) clockwise to seat. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Remove the drill bit. 5. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Old Pedal > Page 2498 Clutch Switch: Adjustments New Pedal Clutch Pedal Position Switch Adjustment (New Pedal) Installation Procedure 1. While holding the pedal in the fully released position, press the switch (2) toward the pedal until the barrel of the switch (2) touches the shipping clip (1). 2. Remove the shipping clip (1). 3. Connect the electrical connector (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Page 2499 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Rotate the CPP switch (1) counterclockwise to release, and remove the switch from the clutch pedal assembly. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Page 2500 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Rotate the switch (1) clockwise to secure. 5. Remove the drill bit. 6. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2514 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2515 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2516 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 2525 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2535 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2536 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2537 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 2546 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2562 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 2568 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 2569 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 2573 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 2574 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2583 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2584 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2585 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2591 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2592 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 2593 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 2597 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 2598 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 2599 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 2600 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 2601 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2605 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 Power Window Switch: Connector Views Window Switch - Driver (Coupe) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Window Switch - Driver C1 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 Window Switch - Driver C2 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Window Switch - RR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Window Switch - Passenger (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 Window Switch - LR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front Power Window Switch: Service and Repair Power Window Switch Replacement - Left Front Power Window Switch Replacement - Left Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 2700 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 2701 Power Window Switch: Service and Repair Power Window Switch Replacement - Right Front Power Window Switch Replacement - Right Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2706 Windshield Wiper/Washer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2707 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch harness connector. 3. Remove the wipers/washer signal switch retaining screws. 4. Remove the wipers/washer signal switch from the steering column. INSTALLATION PROCEDURE 1. Install the wipers/washer signal switch to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the wipers/washer signal switch screws to 2 N.m (17 lb in). 2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2711 Windshield Wiper/Washer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2712 Wiper Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch harness connector. 3. Remove the wipers/washer signal switch retaining screws. 4. Remove the wipers/washer signal switch from the steering column. INSTALLATION PROCEDURE 1. Install the wipers/washer signal switch to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the wipers/washer signal switch screws to 2 N.m (17 lb in). 2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2718 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2719 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2720 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2721 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2722 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2723 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 2724 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications The content of this article reflects the changes identified in TSB 05-03-06-003. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 2727 Alignment: Specifications Wheel Alignment Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 2728 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2729 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2730 Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2731 If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ A large difference in the right and left front tire pressure ^ Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2732 Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2733 Alignment: Service and Repair Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Front Camber Adjustment 1. Loosen both strut to knuckle nuts just enough to allow for movement. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2734 2. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. 2. File the lower hole until the groove of the stamped ring around the hole. 3. Connect the strut to the knuckle. 3. Adjust the camber to specification by moving the top of the wheel in or out. Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (5). 3. Adjust the toe to specification by turning the adjuster (6). Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the tie rod jam nut (5). ^ Tighten the tie rod jam nut (5) to 68 Nm (50 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2741 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2742 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cracking times. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2743 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2744 Steps 7 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: Customer Interest Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 2753 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: All Technical Service Bulletins Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 2759 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2760 Idle Speed: By Symptom Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2761 Disclaimer Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2762 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2763 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Intake Duct Replacement AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front tire and wheel. 2. Remove the left front fender liner. 3. Remove the air cleaner intake duct assembly push-in fasteners. 4. Remove the air cleaner intake duct assembly bolt. 5. Remove the intake duct assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the intake duct assembly. 2. Install the intake duct assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb ft). 3. Install the intake duct assembly push in fasteners. 4. Install the left front fender liner. 5. Install the left front tire and wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 2769 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly air duct at the outlet duct clamp 1. 2. Loosen the outlet duct clamp 2 at the throttle body. 3. Remove the air outlet duct. INSTALLATION PROCEDURE 1. Install the air outlet duct. 2. Install the air outlet duct clamps 1 and 2. 3. Tighten the air outlet duct clamps 1 and 2. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 2770 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2779 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2785 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2786 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Loosen the air cleaner cover screws (1). 3. Remove the air cleaner cover (2). 4. Remove the air cleaner filter from the air cleaner housing (3). INSTALLATION PROCEDURE 1. Install the air cleaner filter into the air cleaner housing. 2. Install the air cleaner cover to the air cleaner housing. 3. Install the air cleaner housing cover screws (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2787 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air cleaner housing screws to 3 N.m (27 lb in). 4. Install the air cleaner assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2793 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2794 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... .................................... 25 - 30 Nm (18.4 - 22.1 lb ft) Spark Plug Gap ................................................ ............................................................................................................................................... 1 mm (0.04 in) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2801 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................... GM P/N 12787099 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2802 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2803 - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2804 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coils. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT coat the spark plugs with anti-seize compound. Over torquing could occur and damage to the cylinder head threads may Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2805 result. Tighten the spark plugs to 20 N.m (15 lb ft). 3. Install the ignition coils. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70 percent of the highest. No cylinder reading should be less than 689 kPa (100 psi) Compression Ratio ................................................................. ...................................................................................................................................... 9.5:01 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2809 Compression Check: Testing and Inspection Engine Compression Test Perform the following steps to conduct a compression test. 1. Conduct the following steps to check cylinder compression. 1. Engine should be at room temperature. 2. Disconnect wiring from the ignition module. 3. Remove the spark plugs. 4. Throttle body valve should be wide open. 5. Battery should be at or near full charge. 2. For each cylinder, crank engine through 4 compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal. Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings. Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves. Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately 3 squirts from a plunger-type oiler. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2817 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2818 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2819 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2822 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2823 The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2824 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2825 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2826 that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2827 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2828 similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2829 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2830 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2831 The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2832 mis-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2833 may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2834 The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2835 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2836 Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2837 may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2838 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the right front fender liner. 2. Important: The drive belt tensioner is a hydraulic tensioner with high initial torque. Release slowly to ensure proper operation. Using an open end wrench, rotate the drive belt tensioner counter clockwise to release the spring tension. 3. Remove the drive belt. Installation Procedure 1. Using an open end wrench, rotate the drive belt tensioner counter clockwise to release the spring tension. 2. Install the drive belt. 3. Install the right front fender liner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Intake Duct Replacement AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front tire and wheel. 2. Remove the left front fender liner. 3. Remove the air cleaner intake duct assembly push-in fasteners. 4. Remove the air cleaner intake duct assembly bolt. 5. Remove the intake duct assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the intake duct assembly. 2. Install the intake duct assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb ft). 3. Install the intake duct assembly push in fasteners. 4. Install the left front fender liner. 5. Install the left front tire and wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 2845 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly air duct at the outlet duct clamp 1. 2. Loosen the outlet duct clamp 2 at the throttle body. 3. Remove the air outlet duct. INSTALLATION PROCEDURE 1. Install the air outlet duct. 2. Install the air outlet duct clamps 1 and 2. 3. Tighten the air outlet duct clamps 1 and 2. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 2846 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2855 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2861 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2862 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Loosen the air cleaner cover screws (1). 3. Remove the air cleaner cover (2). 4. Remove the air cleaner filter from the air cleaner housing (3). INSTALLATION PROCEDURE 1. Install the air cleaner filter into the air cleaner housing. 2. Install the air cleaner cover to the air cleaner housing. 3. Install the air cleaner housing cover screws (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2863 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air cleaner housing screws to 3 N.m (27 lb in). 4. Install the air cleaner assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations PASSENGER COMPARTMENT AIR FILTER The Access Panel for the Passenger Compartment Air Filter is located in the back of the glove compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2867 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT REMOVAL PROCEDURE 1. Open the I/P compartment. The access door for the passenger compartment air filter is located behind the glove box. 2. Tilt the I/P compartment door down by squeezing in on each side of the bin until the door stops can be removed from the tracks. 3. Lower the I/P compartment completely. 4. Open the passenger compartment filter door by reaching through the opening in the rear of the I/P compartment and raising the tab until the door can be opened downward. 5. Remove the filter by sliding the filter out of the passenger compartment filter housing. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2868 IMPORTANT: Make certain that the air flow indicator is pointing down. 1. Install the new filter by sliding the filter into the passenger compartment filter housing. 2. Close the passenger compartment filter door and snap the tab down to latch the door. 3. Raise the I/P compartment door until the door stops contact the frame. Slowly raise the door until the doorstops snap into their tracks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER FILTER REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Clean away any debris that may be present around the evaporative emission (EVAP) canister vent filter cover. 3. Carefully release the canister filter cover rear retaining tabs. 4. Carefully release the canister filter cover forward retaining tabs and remove the cover from the EVAP canister. 5. Remove the filter from the canister and discard the filter. 6. Remove the seal from the filter cover and discard the seal. 7. Clean the inside of the EVAP canister filter housing with a clean shop towel. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 2872 1. Install a NEW seal to the filter cover. Ensure that the seal is properly seated to the cover. 2. Install a NEW filter to the canister filter housing. 3. Install the filter cover to the EVAP canister. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement ^ Tools Required: J 6125-1B Slide Hammer - J 23129 Axle Boot Remover Removal Procedure 1. Raise and support the vehicle. Caution: Refer to Vehicle Lifting Caution in Service Precautions. 2. Place the drain pan under the transaxle oil pan. 3. Remove the oil pan bolts from only the front and the sides. Notice: When removing the oil pan bolts, be careful not to damage the oil pan sealing surfaces. Such damage may result in oil leaks in this area. 4. Loosen the rear oil pan bolts about 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the fluid to drain. 6. Inspect the fluid color. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2876 9. Remove the oil pan gasket. 10. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 11. Check the oil filter seal for damage or wear. 12. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of J 36850 or petroleum jelly. 2. Install a new filter into the case. 3. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged. 4. Clean and dry the oil pan. Inspect the pan for damage and replace the pan if necessary. 5. Install the oil pan. 6. Clean and dry the oil pan. Inspect the pan for damage and replace the pan if necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2877 7. Install the oil pan. 8. Notice: Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 9. Lower the vehicle. 10. Fill the transaxle to the proper level with DEXRON(r) III fluid or the equivalent. 11. Inspect the pan for leaks. Recheck the transmission fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2883 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2884 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2892 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Lower the vehicle. 5. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. 6. Loosen the oil filter housing. 7. Remove the tools. 8. Remove the oil filter and housing. 9. Remove the filter from the cap. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2893 1. Install the filter to the housing. 2. Install the oil filter cap with filter. 3. Install the oil filter to the housing. 4. Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Fill the engine with oil. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair Refrigerant Filter: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 3. Remove and discard the seal washer. 4. Remove the refrigerant filter from the condenser tube. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Page 2897 1. Install the refrigerant filter into the condenser tube. 2. Install new sealing washers on the condenser tube and evaporator hose fittings. 3. Install the condenser tube and evaporator hose to the TXV. 4. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 20 N.m (15 lb ft). 5. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Remove the surge tank cap. 2. Slide a drain pan under the front of the dashboard under the heater inlet hose. 3. Reposition the heater inlet hose clamp at the heater core using J 38185. 4. Remove the heater inlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2903 5. Reposition the heater inlet hose clamp at the engine using J 38185. 6. Remove the heater inlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater inlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2904 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the surge tank cap. CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 2. Place a drain pan under the heater hoses near the front of the dash. 3. Remove the dash panel exterior sound barrier. 4. Reposition the heater outlet hose clamp at the heater core using J 38185. 5. Remove the heater outlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2905 6. Reposition the hose heater outlet hose clamp at the engine using J 38185. 7. Remove the heater outlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater outlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2906 7. Install the dash panel exterior sound barrier. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement Hose/Line HVAC: Technical Service Bulletins A/C - Revised Compressor Hose Assembly Replacement Bulletin No.: 06-01-37-003 Date: March 17, 2006 SERVICE MANUAL UPDATE Subject: Revised Compressor Hose Assembly Replacement (RPO LSJ) Models: 2005-2006 Chevrolet Cobalt with 2.0L Engine (VIN P - RPO LSJ) This bulletin is being issued to revise the Compressor Hose Assembly Replacement (RPO LSJ) procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Compressor Hose Assembly Replacement Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 2911 5. Remove the mounting cover from the charge air cooler pump and position the pump forward. 6. Disconnect the electrical connector from the pressure transducer. 7. Remove the compressor and condenser hose assembly bolt from the compressor. 8. Remove the compressor and condenser hose assembly from the compressor. 9. Remove and discard the sealing washers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 2912 10. Remove the compressor hose from the condenser. 11. Remove and discard the seal washer. Installation Procedure 1. Route the compressor hose to the evaporator hose. 2. Install new sealing washers on the compressor and condenser hose fittings. Refer to Sealing Washer Replacement. 3. Install the A/C compressor and condenser hose assembly to the compressor. Note: Refer to Fastener Notice in Cautions and Notices. 4. Install the A/C compressor and condenser hose assembly bolt. Tighten Tighten the bolt to 20 N.m (15 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 2913 5. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 6. Install the compressor hose and bolt to the condenser. Tighten Tighten the bolt to 20 N.m (15 lb ft). 7. Connect the pressure transducer electrical connector. 8. Install the charge cooler pump. Tighten Tighten the bolts to 10 N.m (88 lb in). 9. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 2914 10. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 11. Install the compressor hose and nut to the evaporator hose. Tighten Tighten the nut to 20 N.m (15 lb ft). 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using the J 39400-A. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube Hose/Line HVAC: Service and Repair Condenser Tube CONDENSER TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the condenser tube bolt and tube from the condenser. 4. Remove and discard the sealing washers. 5. Lower the vehicle. 6. Remove the condenser tube from the frame rail. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2917 7. Remove the condenser tube from the front of dash. 8. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 9. Remove and discard the seal washer. INSTALLATION PROCEDURE 1. Install new sealing washers on the condenser tube and evaporator hose fittings. 2. Install the condenser tube and evaporator hose to the TXV. 3. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2918 Tighten the nut to 20 N.m (15 lb ft). 4. Install the condenser tube to the front of dash. Tighten the nut to 10 N.m (88 lb in). 5. Install the condenser tube to the frame rail. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Install a new seal washer to the condenser tube. 8. Install the condenser tube and bolt to the condenser. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2919 Tighten the bolt to 20 N.m (15 lb ft). 9. Lower the vehicle. 10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2920 Hose/Line HVAC: Service and Repair Compressor Hose Assembly The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-01-37-003 Date: March 17, 2006 SERVICE MANUAL UPDATE Subject: Revised Compressor Hose Assembly Replacement (RPO LSJ) Models: 2005-2006 Chevrolet Cobalt with 2.0L Engine (VIN P - RPO LSJ) Compressor Hose Assembly Replacement Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 5. Remove the mounting cover from the charge air cooler pump and position the pump forward. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2921 6. Disconnect the electrical connector from the pressure transducer. 7. Remove the compressor and condenser hose assembly bolt from the compressor. 8. Remove the compressor and condenser hose assembly from the compressor. 9. Remove and discard the sealing washers. 10. Remove the compressor hose from the condenser. 11. Remove and discard the seal washer. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2922 1. Route the compressor hose to the evaporator hose. 2. Install new sealing washers on the compressor and condenser hose fittings. 3. Install the A/C compressor and condenser hose assembly to the compressor. Note: Refer to Fastener Notice in Cautions and Notices. 4. Install the A/C compressor and condenser hose assembly bolt. Tighten the bolt to 20 N.m (15 lb ft). 5. Install a new seal washer to the compressor hose. 6. Install the compressor hose and bolt to the condenser. Tighten the bolt to 20 N.m (15 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2923 7. Connect the pressure transducer electrical connector. 8. Install the charge cooler pump. Tighten the bolts to 10 N.m (88 lb in). 9. Lower the vehicle. 10. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 11. Install the compressor hose and nut to the evaporator hose. Tighten the nut to 20 N.m (15 lb ft). 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2924 Hose/Line HVAC: Service and Repair Suction Screen Installation SUCTION SCREEN INSTALLATION TOOLS REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-6 Sizing Tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to the J 44551-5 Screen Installation Tool. 4. Install the J 44551-5 (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of the J 44551-5.The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT: Correct placement of the J 44551-5 is critical. 6. Remove the J 44551-5 from the suction hose. 7. Install the J 44551-1 Suction Screen Notification Label. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2925 Hose/Line HVAC: Service and Repair Evaporator Hose Assembly EVAPORATOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Remove the retainer clamp from the evaporator hose. 5. Remove the condenser tube and the evaporator hose from the thermal expansion valve (TXV). IMPORTANT: You may have to position the wires aside to remove the evaporator hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 2926 6. Remove and discard the seal washers. INSTALLATION PROCEDURE 1. Install new sealing washers on the condenser tube and evaporator hose fittings. 2. Install the condenser tube and evaporator hose to the TXV. 3. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 20 N.m (15 lb ft). 4. Install the new seal washer to the compressor hose. 5. Install the compressor hose and nut to the evaporator hose. Tighten the nut to 20 N.m (15 lb ft). 6. Install the retainer clamp to the evaporator hose. 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet (2.0L (LSJ) ^ Tools Required SA9111E Constant Force Clamp Pliers Removal Procedure 1. Partially remove the splash shields from the right fender liner to gain access to the drain cock. 2. Partially drain the cooling system. 3. Lower the vehicle. 4. Reposition the radiator inlet hose clamp at the radiator using SA9111E. 5. Remove the radiator inlet hose from the radiator. 6. Reposition the radiator inlet hose clamp at the engine using SA9111E. 7. Remove the radiator inlet hose from the engine. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2931 1. Install the radiator inlet hose to the radiator. 2. Reposition the radiator inlet hose clamp to secure the hose using SA9111E. 3. Install the radiator inlet hose to the engine. 4. Reposition the radiator inlet hose clamp to secure the hose using SA9111E. 5. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2932 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet (2.0L (LSJ) ^ Tools Required SA9111E Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Lower the vehicle. 3. Remove the air intake duct. 4. Remove the fan shroud. 5. Reposition the radiator outlet hose clamp at the radiator using SA9111E. 6. Remove the radiator outlet hose from the radiator. 7. Remove the underhood electrical center. 8. Reposition the radiator outlet hose clamp at the engine using SA9111E. 9. Remove the radiator outlet hose from the engine. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2933 1. Install the radiator outlet hose to the radiator. 2. Reposition the radiator outlet hose clamp to secure the hose using SA9111E. 3. Install the underhood electrical center. 4. Install the radiator outlet hose to the engine. 5. Reposition the radiator outlet hose clamp to secure the hose using SA9111E. 6. Install the fan shroud. 7. Install the air intake duct. 8. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 2939 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 2944 Clutch Fluid: Fluid Type Specifications HYDRAULIC CLUTCH FLUID Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2949 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2950 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2951 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2952 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ................................................... 7.4 quarts (7.0 liter) Intercooler System Capacity ........................... ........................................................................................................................................ 2.0 quarts (1.9 liter) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2955 Coolant: Fluid Type Specifications ENGINE COOLANT AND INTERCOOLER SYSTEM COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2960 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2961 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 2962 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Capacity Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 6.6L (7.0 Qt) 4T40-E/4T45-E Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 6.5L (6.9 Qt) Overhaul ........................... .............................................................................................................................................................. ................... 9.0L (9.5 Qt) Dry .............................................................................................................. .................................................................................................. 12.2L (12.9 Qt) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2965 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2966 Fluid - A/T: Service and Repair TRANSAXLE FLUID CHECKING PROCEDURE NOTE: It is not necessary to check the transmission fluid level. A transmission fluid leak is the only reason for fluid loss. If a leak occurs have it repaired as soon as possible. The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near Room temperature or at 40°C (104°F). CAUTION: Removal of the fluid level screw when the transaxle fluid is hot may cause injury. Use care to avoid contact of transaxle fluid to exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. WARNING: Do not turn the engine off with the fluid level screw removed as you can be injured by hot transaxle fluid being expelled out of the fluid check hole. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. 6. Place oil container under fluid level screw. 7. Remove the fluid level screw with the engine running at idle. 8. Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID. 9. Install fluid level screw. Tighten 12 Nm (106 lb. in.) 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid: With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten 12 Nm (106 lb. in.) 2. Lower vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 05560 > Sep > 05 > Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Fluid - M/T: Recalls Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Transmission Fluid Fill # 05560 - (Sep 15, 2005) Models: Certain 2005-06 Chevrolet Cobalt and Pontiac Pursuit (Canada only) Equipped with Getrag 5-Speed Manual Transmission (RPO M86) An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible, but no later than November 30, 2005, at which time this bulletin will expire. Condition Some late production 2005 and early production 2006 Chevrolet Cobalt and Pontiac Pursuit (Canada only) model vehicles with RPO M86 5 Speed manual transmissions were not filled with the specified Dexron III transmission fluid. Correction Dealers are to replace the transmission fluid in dealer stock vehicles with Dexron III transmission fluid. Service Procedure Refer to SI document number 869140 for the manual transmission fluid replacement procedure. Parts Information Warranty Information Dealers This correction should be performed on all vehicles currently in your inventory that are included in the VIN list contained in the Administrative Message (GM US) Dealer Communication (Canada) prior to sale or delivery. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 05560 > Sep > 05 > Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Fluid - M/T: All Technical Service Bulletins Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Transmission Fluid Fill # 05560 - (Sep 15, 2005) Models: Certain 2005-06 Chevrolet Cobalt and Pontiac Pursuit (Canada only) Equipped with Getrag 5-Speed Manual Transmission (RPO M86) An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible, but no later than November 30, 2005, at which time this bulletin will expire. Condition Some late production 2005 and early production 2006 Chevrolet Cobalt and Pontiac Pursuit (Canada only) model vehicles with RPO M86 5 Speed manual transmissions were not filled with the specified Dexron III transmission fluid. Correction Dealers are to replace the transmission fluid in dealer stock vehicles with Dexron III transmission fluid. Service Procedure Refer to SI document number 869140 for the manual transmission fluid replacement procedure. Parts Information Warranty Information Dealers This correction should be performed on all vehicles currently in your inventory that are included in the VIN list contained in the Administrative Message (GM US) Dealer Communication (Canada) prior to sale or delivery. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................................. 1.7L (1.8 Qt) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2982 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................................. Dexron III Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Getrag 5 Speed Fluid - M/T: Service and Repair Getrag 5 Speed Transmission Fluid Replacement Draining Procedure 1. Remove the left front wheel. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting 3. Clean away all dirt and debris from the transmission fluid drain plug area. 4. Remove the drain plug. 5. Allow the system to drain. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission fluid drain plug, using pipe sealant Saturn P/N 21485278 or equivalent on the plug threads. ^ Tighten the transmission fluid drain plug to 38 Nm (28 ft. lbs.). Filling Procedure 1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the transmission fluid level check plug. 3. Fill the transmission with DEXRON-III transmission fluid Saturn P/N 21019223, until even with the bottom of the fill plug hole. 4. Install the level check plug. ^ Tighten the level check plug to 38 Nm (28 ft. lbs.). 5. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 2985 Fluid - M/T: Service and Repair MU3 Transmission Fluid Replacement 1. Important: The manual transaxle is filled with fluid at the manufacturer and requires no routine oil changes. If it is determined that the fluid needs to be changed due to contamination or a similar issue, follow this procedure. Important: To ensure that all sediment within the transaxle is suspended in the fluid, the fluid should only be drained after it has reached a normal operating temperature of 88 - 93°C (190 200°F). Normal operating temperature is reached after approximately 25 km (15 miles) of highway driving. Position vehicle on hoist and raise vehicle. Refer to Vehicle Lifting 2. Caution: The transaxle fluid is hot. Caution must be taken to prevent personal injury when the transaxle fluid drains from the transaxle. Remove the transaxle drain plug (1). 3. Remove the transaxle level plug (2). 4. Clean and apply thread sealant P/N 21485278 to the drain plug (1) and install. ^ Tighten the transaxle drain plug to 50 Nm (37 ft. lbs.). 5. Using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle lubricant P/N 21018899 through the level plug (2) opening until fluid flows out. 6. Clean and apply thread sealant P/N 21485278 to the level plug (2) and install. ^ Tighten the transaxle level plug to 50 Nm (37 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2990 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2991 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... .............................................................. 4.7L (5.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2994 Engine Oil: Fluid Type Specifications Look for two things: 1. GM4718M Your vehicle's engine requires a special oil meeting GM Standard GM4718M. Oils meeting this standard may be identified as synthetic. However, not all synthetic oils will meet this GM standard. You should look for and use only an oil that meets GM Standard GM4718M. NOTICE: If you use oils that do not have the GM4718M Standard designation, you can cause engine damage not covered by your warranty. 2.SAE 5W-30 As shown in the viscosity chart, SAE 5W-30 is best for your vehicle. However, you can use SAE 10W-30 if it is going to be 0°F (-18°C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this on the oil container, and use only those oils that are identified as meeting GM Standard GM4718M and have the starburst symbol on the front of the oil container. Your vehicle's engine is filled at the factory with a Mobil 1 synthetic oil, which meets all requirements for your vehicle. SUBSTITUTE ENGINE OIL: When adding oil to maintain engine oil level, oil meeting GM Standard GM4718M may not be available. You can add substitute oil designated SAE 5W-30 with the starburst symbol at all temperatures. If temperatures are above 0°F (-18°C), you may substitute SAE 10W-30 with the starburst symbol. Substitute oil not meeting GM Standard GM4718M should not be used for an oil change. ENGINE OIL ADDITIVES Do NOT add engine oil additives. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2995 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Lower the vehicle. 5. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. 6. Loosen the oil filter housing. 7. Remove the tools. 8. Remove the oil filter and housing. 9. Remove the filter from the cap. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2996 1. Install the filter to the housing. 2. Install the oil filter cap with filter. 3. Install the oil filter to the housing. 4. Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Fill the engine with oil. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Information not provided by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 3001 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy Refrigerant: Customer Interest A/C - Not Cold Enough/Compressor Noisy Bulletin No.: 05-01-38-005A Date: July 29, 2005 TECHNICAL Subject: A/C System Not Cold Enough, Noisy A/C Compressor (Recharge A/C System With Correct Amount of Refrigerant) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To December 6, 2004 Supercede: This bulletin is being revised to add a build date for when the condition was corrected on production vehicles. Please discard Corporate Bulletin Number 05-01-38-005 (Section 01 - HVAC). Condition Important: The refrigerant charge amount was corrected on vehicles built beginning on December 6, 2004. Vehicles built before this date may have an incorrect refrigerant charge amount. Some customers may comment on the Air Conditioning (A/C) system not blowing cold air. Others may comment that the windshield does not clear as quickly as expected while in the defrost mode. Technicians may hear a noise in the engine compartment coming from the A/C compressor. Cause If the Service Engine Soon (SES) light is not on, the root cause of the customer concern may be an overcharge of A/C system refrigerant. Correction Technicians are to recover, evacuate and then recharge the A/C system with the correct amount of refrigerant using the following procedure: 1. Open the hood and connect a J43600 ACR2000 Air Conditioning Service Center to the vehicle. 2. Start the vehicle and turn on the A/C system. 3. Verify that the A/C compressor is operating and that the Service Engine Soon light is not on. If the A/C system is not operating or the Service Engine Soon light is on, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 4. Turn off the ignition. 5. Recover, evacuate and then recharge the A/C system. 6. Start the vehicle and verify proper operation of the A/C system. 7. If the A/C system does not operate properly or is still noisy, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 8. Disconnect the ACR2000 and close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy > Page 3010 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant: > 08-01-38-001 > Jan > 08 > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant > Page 3020 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy Refrigerant: All Technical Service Bulletins A/C - Not Cold Enough/Compressor Noisy Bulletin No.: 05-01-38-005A Date: July 29, 2005 TECHNICAL Subject: A/C System Not Cold Enough, Noisy A/C Compressor (Recharge A/C System With Correct Amount of Refrigerant) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To December 6, 2004 Supercede: This bulletin is being revised to add a build date for when the condition was corrected on production vehicles. Please discard Corporate Bulletin Number 05-01-38-005 (Section 01 - HVAC). Condition Important: The refrigerant charge amount was corrected on vehicles built beginning on December 6, 2004. Vehicles built before this date may have an incorrect refrigerant charge amount. Some customers may comment on the Air Conditioning (A/C) system not blowing cold air. Others may comment that the windshield does not clear as quickly as expected while in the defrost mode. Technicians may hear a noise in the engine compartment coming from the A/C compressor. Cause If the Service Engine Soon (SES) light is not on, the root cause of the customer concern may be an overcharge of A/C system refrigerant. Correction Technicians are to recover, evacuate and then recharge the A/C system with the correct amount of refrigerant using the following procedure: 1. Open the hood and connect a J43600 ACR2000 Air Conditioning Service Center to the vehicle. 2. Start the vehicle and turn on the A/C system. 3. Verify that the A/C compressor is operating and that the Service Engine Soon light is not on. If the A/C system is not operating or the Service Engine Soon light is on, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 4. Turn off the ignition. 5. Recover, evacuate and then recharge the A/C system. 6. Start the vehicle and verify proper operation of the A/C system. 7. If the A/C system does not operate properly or is still noisy, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 8. Disconnect the ACR2000 and close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy > Page 3025 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 08-01-38-001 > Jan > 08 > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant > Page 3035 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 1.0 lbs (0.45 kg) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3038 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3039 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ABRUPT REFRIGERANT LOSS ........................................................................................................................................................... 60 ml (2.0 oz) NOTE: Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 74 ml (2.5 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. CONDENSER REPLACEMENT .......................................................................................................................................................... 22 ml (0.75 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. EVAPORATOR REPLACEMENT ....................................................................................................................................................... 22 ml (0.75 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 148 ml (5.0 oz) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3046 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL Polyalkylene glycol (PAG) Oil ................................................................................................................ GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 3047 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base brake system. The automated bleed procedure is recommended when one of the following conditions exist: ^ Base brake system bleeding does not achieve the desired pedal height or feel ^ Extreme loss of brake fluid has occurred ^ Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure 1. Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. Raise and support the vehicle. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. 10. Following the directions given on the scan tool, pressure bleed the base brake system. 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle, and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. 17. Inspect the brake fluid level. 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3052 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 21. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3053 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice; When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532, or equivalent, to the J 44894-A. 7. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 8. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks.Any brake fluid leaks identified require repair prior to completing this procedure. 10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 20. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 44894-A. 21. Remove the J 44894-A from the brake master cylinder reservoir. 22. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3054 2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). 24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 25. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3055 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir, if bleeding from a manual transmission vehicle ensure to cap or plug the clutch hose port while bleeding the master cylinder. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3060 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3061 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3062 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3063 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3064 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3065 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3066 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3067 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3068 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3069 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3070 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3071 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3072 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3073 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3074 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3075 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3076 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3077 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3078 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3079 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3080 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3081 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3082 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3083 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3084 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3085 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 3086 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover Fuse: Locations Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3094 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3095 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3096 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3097 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3098 Fuse: Locations Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3099 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3100 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3101 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3102 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3103 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 3104 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Connector Views Fuse Holder - 50 AMP Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover Fuse: Application and ID Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3109 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3110 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3111 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3112 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3113 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3114 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3115 Fuse: Application and ID Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3116 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3117 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3118 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3119 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3120 Application Table Part 2 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 3121 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - Underhood C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3126 Fuse Block - Underhood C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3127 Fuse Block - Underhood C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3128 Fuse Block - Underhood C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3129 Fuse Block - Underhood C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3130 Fuse Block - Underhood C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3131 Fuse Block - Underhood C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3132 Fuse Block - Underhood C4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3133 Fuse Block - Underhood C5 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3134 Fuse Block - Underhood C5 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 3135 Fuse Block - Underhood C6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 3136 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 3137 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Page 3141 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied directly to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1 - 6 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3148 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3149 Steps 1 - 11 The number below refers to the step number on the diagnostic table. 3. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation ENGINE OIL LIFE SYSTEM WHEN TO CHANGE ENGINE OIL Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A "CHANGE OIL SOON" message in the Driver Information Center (DIC) will come on. Change your oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 3153 Oil Change Reminder Lamp: Service and Repair ENGINE OIL LIFE SYSTEM HOW TO RESET THE ENGINE OIL LIFE SYSTEM The Engine Oil Life System calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a CHANGE OIL SOON message being turned on, reset the system. After changing the engine oil, the system must be reset as follows: 1. Turn the ignition to "RUN", with the engine off. 2. Press the "information" and "reset" buttons on the DIC at the same time to enter the personalization menu. 3. Press the "information" button to scroll through the available personalization menu modes until the DIC display shows "OIL-LIFE RESET". 4. Press and hold the "reset" button until the DIC display shows "ACKNOWLEDGED". This will tell you the system has been reset. 5. Turn the key to "LOCK". If the CHANGE OIL SOON message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the reset procedure. WHAT TO DO WITH USED OIL Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 3158 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Automotive Lift And Floor Jack Contact Points AUTOMOTIVE LIFT AND FLOOR JACK CONTACT POINTS VEHICLE LIFTING-FRAME CONTACT LIFT Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads 6.69 in (170 mm) from the front pinchweld flanges. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads 2.17 in (55 mm) from the rear pinchweld flanges. VEHICLE JACKING Under the Center of the Rear Suspension Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension. SUPPORTING THE VEHICLE WITH JACKSTANDS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 3159 IMPORTANT: Place jackstands ONLY under strong and stable vehicle structures. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3174 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3188 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3193 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3194 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3195 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3196 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3197 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3198 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3199 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3200 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3201 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3202 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 3203 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting Tires: Service and Repair Tire Mounting and Dismounting Tire Mounting and Dismounting Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Deflate the tire completely. Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 2. Use the tire changer in order to remove the tire from the wheel. Important: Rim-clamp European-type tire changers are recommended. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. 4. Apply an approved Lubricant to the tire bead and the wheel rim. Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 5. Use the tire changer in order to install the tire to the wheel. 6. Inflate the tire to the proper air pressure. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting > Page 3206 Tires: Service and Repair Tire Repair Tire Repair Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting > Page 3207 Tires: Service and Repair Tire Rotation Tire Rotation Rotate the tire and wheel assemblies at frequent intervals to equalize wear. In addition to scheduled rotation, rotate the tire and wheel assembly whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then set the tire pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3216 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3217 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3218 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3223 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3228 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3229 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3230 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3236 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3237 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3238 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3243 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3248 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3249 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM Wheels: All Technical Service Bulletins Wheels/Tires - 18 Inch Wheels Available Through GM INFORMATION Bulletin No.: 05-03-10-011E Date: May 26, 2010 Subject: 18 Inch Accessory Wheels Available Through GM Accessories Models: 2005-2007 Chevrolet Cobalt SS Supercharged 2006-2008 Chevrolet Cobalt SS (2 Door Coupe and 4 Door Sedan - Excludes Turbocharged) 2007-2011 Chevrolet HHR, HHR Panel (LT Option with 17" Tires (RPO QBV) Only) (Built After VIN Breakpoint 7S541326) 2006 Pontiac Pursuit GT (Canada Only), G4 GT (Mexico Only) 2007-2010 Pontiac G5 GT Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-03-10-011D (Section 03 - Suspension). The purpose of this bulletin is to provide a reference guide for the technician to upgrade a vehicle from factory wheel and tires to 18" wheels and tires, which are available through GM Accessories. This guide will cover tires, wheels, vehicle modifications, and warranty information. Tires GM offers one tire, the Pirelli P-ZERO ROSSO 215/45R18, to be used in conjunction with the 18" accessory wheels. The Pirelli tire has a Tire Performance Criteria (TPC) spec of #1255, which meets or exceeds all federal safety guidelines. Wheels Center Cap Notice Attempting to "hammer on" the caps may result in damage to the cap. Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is by hand. As an alternate, use a non-metallic object to push the center cap into place. Wheel (Lug) Nuts Caution: Incorrect wheel nuts or improperly tightened wheel nuts may cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be tightened to 140 Nm (100 lb ft) using the tightening sequence illustrated above. The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3254 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3255 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3256 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3261 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3262 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3263 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3268 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3273 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3274 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3275 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3285 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3286 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3287 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3292 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3297 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 3298 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM Wheels: All Technical Service Bulletins Wheels/Tires - 18 Inch Wheels Available Through GM INFORMATION Bulletin No.: 05-03-10-011E Date: May 26, 2010 Subject: 18 Inch Accessory Wheels Available Through GM Accessories Models: 2005-2007 Chevrolet Cobalt SS Supercharged 2006-2008 Chevrolet Cobalt SS (2 Door Coupe and 4 Door Sedan - Excludes Turbocharged) 2007-2011 Chevrolet HHR, HHR Panel (LT Option with 17" Tires (RPO QBV) Only) (Built After VIN Breakpoint 7S541326) 2006 Pontiac Pursuit GT (Canada Only), G4 GT (Mexico Only) 2007-2010 Pontiac G5 GT Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-03-10-011D (Section 03 - Suspension). The purpose of this bulletin is to provide a reference guide for the technician to upgrade a vehicle from factory wheel and tires to 18" wheels and tires, which are available through GM Accessories. This guide will cover tires, wheels, vehicle modifications, and warranty information. Tires GM offers one tire, the Pirelli P-ZERO ROSSO 215/45R18, to be used in conjunction with the 18" accessory wheels. The Pirelli tire has a Tire Performance Criteria (TPC) spec of #1255, which meets or exceeds all federal safety guidelines. Wheels Center Cap Notice Attempting to "hammer on" the caps may result in damage to the cap. Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is by hand. As an alternate, use a non-metallic object to push the center cap into place. Wheel (Lug) Nuts Caution: Incorrect wheel nuts or improperly tightened wheel nuts may cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be tightened to 140 Nm (100 lb ft) using the tightening sequence illustrated above. The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3303 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3304 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 3305 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 3312 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Wheel Bearing/Hub Assembly Mounting Bolts ...................................................................................................................................... 115 Nm (85 ft. lbs.) Rear Wheel Bearing/Hub Assembly Mounting Nuts ...................................................................................................................... 45 Nm +30° (33 ft. lbs. + 30°) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3316 Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3319 Wheel Bearing/Hub Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3320 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Wheel Bearing/Hub Replacement - Rear (Disc Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the rear brake caliper and bracket as an assembly, and remove the rear brake rotor. 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the wheel bearing/hub assembly mounting nuts. 6. Remove the wheel bearing/hub assembly and the disc brake backing plate from the rear axle assembly. Installation Procedure 1. Install the wheel bearing/hub assembly and the brake backing plate to the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3321 3. Connect the electrical connector to the wheel speed sensor. 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Drum Brake Wheel Bearing/Hub Replacement - Rear (Drum Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the plug from the drum brake actuator access hole in the backing plate. Using the access hole, install a support (1) for the brake backing plate. 5. Disconnect the electrical connector (2) from the wheel speed sensor, if equipped with ABS. 6. Remove the wheel bearing/hub assembly mounting nuts (3). 7. Remove the wheel bearing/hub assembly from the rear axle assembly and brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3322 1. Install the wheel bearing/hub assembly to the brake backing plate and the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts (3) to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. 3. Connect the electrical connector (2) to the wheel speed sensor, if equipped with ABS. 4. Remove the support (1) from the brake backing plate. 5. Install the plug to the drum brake actuator access hole in the backing plate. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise Wheel Cover: Customer Interest Tires/Wheels - Wheel Squeak Noise TECHNICAL Bulletin No.: 05-03-10-006D Date: June 02, 2010 Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with 15-Inch Wheel Covers Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 05-03-10-006C (Section 03 - Suspension). Condition Some customers may comment on a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h [0-15 mph]). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction Install insulator tape on the backside of all four wheel covers. Use the following procedure: Chevrolet Cobalt/Pontiac G5 Pontiac Pursuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise > Page 3331 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol (using a clean, lint-free, non-abrasive cloth) at the insulator locations. Refer to the illustrations above. 5. Cut forty 7 mm (0.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside at the outer most edge as shown in the illustrations above. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be 10 insulators placed on each wheel cover. Important Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information *To obtain this product, check your dealer's auto body shop - they may already have this tape. You may also contact the 3M(R) Automotive Aftermarket Helpline at 1-877-666-2277 and follow the menu options to locate a store near you where it can be purchased. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise Wheel Cover: All Technical Service Bulletins Tires/Wheels - Wheel Squeak Noise TECHNICAL Bulletin No.: 05-03-10-006D Date: June 02, 2010 Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with 15-Inch Wheel Covers Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 05-03-10-006C (Section 03 - Suspension). Condition Some customers may comment on a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h [0-15 mph]). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction Install insulator tape on the backside of all four wheel covers. Use the following procedure: Chevrolet Cobalt/Pontiac G5 Pontiac Pursuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise > Page 3337 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol (using a clean, lint-free, non-abrasive cloth) at the insulator locations. Refer to the illustrations above. 5. Cut forty 7 mm (0.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside at the outer most edge as shown in the illustrations above. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be 10 insulators placed on each wheel cover. Important Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information *To obtain this product, check your dealer's auto body shop - they may already have this tape. You may also contact the 3M(R) Automotive Aftermarket Helpline at 1-877-666-2277 and follow the menu options to locate a store near you where it can be purchased. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3343 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3344 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3345 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3350 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3351 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3352 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3353 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3354 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3355 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 3360 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 3365 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3371 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3372 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 3373 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3378 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3379 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3380 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3381 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3382 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 3383 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 3388 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 3393 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Nut ...................................................................................................................................... ................................................. 110 Nm (81 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3406 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3412 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3413 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3414 Wheel Nut Torque Sequence Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension (4-Stud Pattern) Wheel Stud Replacement (4-Stud Pattern) ^ Tools Required J 43631 Ball Joint Remover Notice: Avoid tool contact to the outer constant velocity boot seal when removing the wheel bearing mounting bolts. Failure to observe this notice may result in damage to the CV boot. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. 4. Inspect the head of the wheel stud to be replaced, to determine if the stud is an original, round-head, or a service replacement, D-shape head. Important: It will be necessary to cut off a portion of an original, round-head wheel stud in order to provide clearance to remove the stud from the wheel bearing hub. 5. If an original, round-head wheel stud is to be replaced, then a portion of the stud must be cut off, so that the remainder of the stud will be approximately 10 mm (0.39 inch) long from the face of the bearing hub flange. 6. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 7. Using the J 43631 , release the wheel stud from the bearing hub. If a portion of the stud was cut off, remove and discard the stud. 8. Loosen the 3 wheel bearing/hub assembly mounting bolts evenly, until there is approximately 7 mm (1/4 inch) of clearance between the seat of the bearing assembly and the steering knuckle. This will be necessary for removing and installing a service replacement D-shape head stud. 9. If the stud being replaced was a D-shape head, remove and discard the stud. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3417 Important: The replacement front wheel stud has a D-shape head to provide clearance for installation. 1. With the bearing hub still in position, install the NEW service replacement stud into the bearing/hub assembly. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the wheel bearing/hub assembly mounting bolts evenly to draw the bearing assembly back to the steering knuckle, then tighten the bolts to specifications. ^ Tighten the bolts to 115 Nm (85 ft. lbs.). 3. Add enough washers (1) in order to draw the stud into the hub. 4. Install the wheel nut (2) with the flat side against the washers. 5. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 6. Remove the wheel nut and the washers. 7. Install the brake rotor, and install the brake caliper and bracket as an assembly. 8. Install the tire and wheel assembly. 9. Lower the vehicle. (5-Stud Pattern) Wheel Stud Replacement (5-Stud Pattern) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3418 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. 4. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 5. Using the J 43631 , release the wheel stud from the bearing hub and discard the stud. Installation Procedure 1. With the bearing hub still in position, install the NEW stud into the bearing/hub assembly. 2. Add enough washers (1) in order to draw the stud into the hub. 3. Install the wheel nut (2) with the flat side against the washers. 4. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut and the washers. 6. Install the brake rotor, and install the brake caliper and bracket as an assembly. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3419 Wheel Fastener: Service and Repair Rear Suspension Disc Brake Wheel Stud Replacement (Disc Brake) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake rotor. 4. Using the J 43631 , remove and discard the wheel stud. Installation Procedure 1. Install the NEW wheel stud into the wheel bearing hub. 2. Add enough washers (3) in order to draw the stud into the hub. 3. Install the wheel nut (1) with the flat side against the washers. 4. Tighten the wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut (1) and the washers (3). 6. Install the brake rotor. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Drum Brake Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3420 Wheel Stud Replacement (Drum Brake) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Using the J 43631 , remove and discard the wheel stud. Installation Procedure 1. Install the NEW wheel stud into the wheel bearing hub. 2. Add enough washers (1) in order to draw the stud into the hub. 3. Install the wheel nut (2) with the flat side against the washers. 4. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut and the washers. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: - Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 3424 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery.Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery.Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery.This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3429 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3430 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3431 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3432 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3433 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 3434 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 3438 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Automotive Lift And Floor Jack Contact Points AUTOMOTIVE LIFT AND FLOOR JACK CONTACT POINTS VEHICLE LIFTING-FRAME CONTACT LIFT Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads 6.69 in (170 mm) from the front pinchweld flanges. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads 2.17 in (55 mm) from the rear pinchweld flanges. VEHICLE JACKING Under the Center of the Rear Suspension Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension. SUPPORTING THE VEHICLE WITH JACKSTANDS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 3439 IMPORTANT: Place jackstands ONLY under strong and stable vehicle structures. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70 percent of the highest. No cylinder reading should be less than 689 kPa (100 psi) Compression Ratio ................................................................. ...................................................................................................................................... 9.5:01 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3445 Compression Check: Testing and Inspection Engine Compression Test Perform the following steps to conduct a compression test. 1. Conduct the following steps to check cylinder compression. 1. Engine should be at room temperature. 2. Disconnect wiring from the ignition module. 3. Remove the spark plugs. 4. Throttle body valve should be wide open. 5. Battery should be at or near full charge. 2. For each cylinder, crank engine through 4 compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal. Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings. Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves. Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately 3 squirts from a plunger-type oiler. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolt ................................................................................................................. .................................................. 10 Nm (89 inch lbs.) In increments of 3 turns Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement Camshaft: Service and Repair Intake Camshaft and Lifter Replacement Intake Camshaft and Lifter Replacement ^ Tools Required J 43655 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the upper timing chain guide. 3. Install the J 43655. 4. Remove both the intake and exhaust camshaft sprocket bolts and discard. 5. Slide the camshaft sprockets forward. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3454 6. Mark bearing caps to ensure they are installed in the original position. 7. Important: Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft. Remove the bearing caps. 8. Remove the intake camshaft. 9. Remove the camshaft roller followers. 10. Remove the hydraulic element lash adjusters. Installation Procedure 1. Lubricate the valve tips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3455 2. Install the hydraulic element lash adjusters. 3. Install the camshaft roller followers. 4. Ensure that the alignment notches are aligned with the camshaft sprocket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3456 5. Install the intake camshaft. 6. Install the camshaft bearing caps. 7. Notice: Refer to Fastener Notice in Service Precautions. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. ^ Tighten the camshaft bearing cap bolts to 10 Nm (89 inch lbs.). 8. Apply a 5 mm (0.197 inch) bead of Permatex Anaerobic Gasket Maker 51813 (or equivalent), to the rear intake camshaft bearing cap. 9. Install the rear intake camshaft bearing cap bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 10. Install camshaft sprockets onto the camshafts. 11. Hand tighten NEW camshaft sprocket bolts. 12. Remove the J 43655. 13. Tighten the camshaft sprocket bolts. ^ Tighten the bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 14. Install the upper timing chain guide. ^ Tighten the upper timing chain guide to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3457 15. Install the camshaft cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3458 Camshaft: Service and Repair Exhaust Camshaft and Lifter Replacement Exhaust Camshaft and Lifter Replacement ^ Tools Required J 43655 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the upper timing chain guide. 3. Install the J 43655. 4. Remove both the intake and the exhaust camshaft sprocket bolts and discard. 5. Slide the camshaft sprockets forward. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3459 6. Mark the bearing caps to ensure that the bearing caps are installed in the original position. 7. Important: Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft. Remove the bearing caps. 8. Remove the exhaust camshaft. 9. Remove the camshaft roller followers. 10. Remove the hydraulic element lash adjusters. Installation Procedure 1. Lubricate the valve tips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3460 2. Install the hydraulic element lash adjusters. 3. Install the camshaft roller followers. 4. Ensure that the alignment notches are aligned with the camshaft sprocket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 3461 5. Install the exhaust camshaft. 6. Install the camshaft bearing caps. 7. Notice: Refer to Fastener Notice in Service Precautions. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. ^ Tighten the camshaft bearing cap bolts to 10 Nm (89 inch lbs.). 8. Install camshaft sprockets onto the camshafts. 9. Hand tighten NEW camshaft sprocket bolts. 10. Remove the J 43655. 11. Tighten the camshaft sprocket bolts. ^ Tighten the bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 12. Install the upper timing chain guide. ^ Tighten the upper timing chain guide to 10 Nm (89 inch lbs.). 13. Install the camshaft cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair Balance Shaft: Service and Repair Crankshaft Balancer Replacement ^ Tools Required J 38122-A Harmonic Balancer Holder Removal Procedure 1. Remove the engine drive belt. 2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. 3. Remove the crankshaft balancer bolt. Discard the bolt. 4. Remove the crankshaft balancer. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Page 3466 1. Install the crankshaft balancer. 2. Install a NEW crankshaft balancer bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Use J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. ^ Tighten the bolt to 100 Nm (74 ft. lbs.) plus 75 degrees. 4. Install the engine drive belt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Clearance .......................................................................................................................... 0.029-0.069 mm (0.0011-0.0027 inch) Connecting Rod Bore Diameter - Bearing End ................................................................................................... 52.118-52.134 mm (2.0519-2.05252 inch) Connecting Rod Bore Diameter - Pin End ............................................................................................................ 20.007-20.021 mm (0.7877-0.7882 inch) Connecting Rod Side Clearance ................................................................................................................................ 0.070-0.370 mm (0.0028-0.0146 inch) Connecting Rod Straightness - Bend - Maximum ............................................................................................................................ 0.021 mm (0.0083 inch) Connecting Rod Straightness - Twist - Maximum ............................................................................................................................. 0.04 mm (0.0157 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Connecting Rod Bearing Clearance .......................................................................................................................... 0.029-0.069 mm (0.0011-0.0027 inch) Connecting Rod Bore Diameter - Bearing End ................................................................................................... 52.118-52.134 mm (2.0519-2.05252 inch) Connecting Rod Bore Diameter - Pin End ............................................................................................................ 20.007-20.021 mm (0.7877-0.7882 inch) Connecting Rod Side Clearance ................................................................................................................................ 0.070-0.370 mm (0.0028-0.0146 inch) Connecting Rod Straightness - Bend - Maximum ............................................................................................................................ 0.021 mm (0.0083 inch) Connecting Rod Straightness - Twist - Maximum ............................................................................................................................. 0.04 mm (0.0157 inch) Connecting Rod Bolts First Pass ......................................................................................................... .......................................................................................... 25 Nm (18 ft. lbs.) Final Pass ................... .............................................................................................................................................................. ........................... 100 degrees Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Lower Crankcase to Block Bolts First Pass ............................................................................................................................................. ...................................................... 20 Nm (15 ft. lbs.) Final Pass ....................................................... ....................................................................................................................................................... 70 degrees Crankshaft Connecting Rod Journal Diameter ........................................................................................................................ 49.000-49.014 mm (1.9291-1.9297 inch) Crankshaft End Play .................................................................................................................................................. 0.050-0.380 mm (0.0012-0.0150 inch) Crankshaft Main Bearing Clearance ......................................................................................................................... 0.031-0.067 mm (0.0012-0.0026 inch) Crankshaft Main Journal Diameter ....................................................................................................................... 55.994-56.008 mm (2.2045-2.2050 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Connecting Rod Journal Diameter ........................................................................................................................ 49.000-49.014 mm (1.9291-1.9297 inch) Crankshaft End Play .................................................................................................................................................. 0.050-0.380 mm (0.0012-0.0150 inch) Crankshaft Main Bearing Clearance ......................................................................................................................... 0.031-0.067 mm (0.0012-0.0026 inch) Crankshaft Main Journal Diameter ....................................................................................................................... 55.994-56.008 mm (2.2045-2.2050 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure Technical Service Bulletin # 03-06-01-018D Date: 060405 Engine - Revised Cylinder Sleeve Replacement Procedure Bulletin No.: 03-06-01-018D Date: April 05, 2006 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2002-2005 Chevrolet Cavalier 2004-2006 Chevrolet Classic, Malibu 2005-2006 Chevrolet Cobalt, Cobalt SS 2006 Chevrolet HHR 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Sunfire 2002-2006 Pontiac Grand Am 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Soltice with Ecotec 2.0L, 2.2L or 2.4L 4-Cylinder Engine (VINs P, F, B - RPOs LSJ, L61, LE5) Supercede: This bulletin is being revised to provide updated cylinder sleeve replacement procedures. Please discard Corporate Bulletin Number 03-06-01-018C (Section 06 - Engine). This bulletin is being issued to update cylinder sleeve replacement in the Engine Mechanical sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The new procedure for the 2.0L, 2.2L and 2.4L four cylinder engines has been developed to replace the cylinder bore sleeve when the engine is in or out of the vehicle. Tools Required EN45680-850 Cylinder Sleeve Removal and Installation Kit Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3483 For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3484 Disclaimer Procedures Removal Procedure Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. Remove the cylinder head. 2. Remove the oil pan. Refer to Oil Pan Replacement. 3. Remove the piston and connecting rod. Refer to Piston, Connecting Rod, and Bearing Removal. 4. Inspect the condition of the piston. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. 5. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 6. Install the EN 45680-852 cylinder bore sleeve puller (1) through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore liner or damage to the cylinder bore liner puller EN45680-852 will occur. 7. Align the shoe (1) of the EN 45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3485 8. Hold the threaded shaft of the EN 45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 9. Install the EN 456850-851 fixture (4) onto the threaded shaft of the EN 456850-852 cylinder bore sleeve puller and the engine block. 10. Install the bearing (3) and the nut (1). 11. Tighten the nut (1) to the bearing (3). Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Use 4 old cylinder head bolts for the attaching bolts 12. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 N.m (11 lb-ft). 13. Rotate the nut clockwise in order to remove the cylinder bore liner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3486 Note: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. 14. Remove EN 45680-851 fixture, EN 45680-852 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block. 15. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Installation Procedure Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve onto the cylinder block. 2. Install EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3487 Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the EN 45680-851 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten Tighten the 4 attachment bolts to 15 N.m (11 lb-ft). 4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3488 5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2). 6. Align the pusher block (2) of EN 45680-853 cylinder bore sleeve installer into the groove of EN 45680-851 fixture (1). Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-851/cylinder bore liner installer EN 45680-853 assembly or damage to the cylinder bore liner will occur. 7. Using a ratchet, rotate the threaded shaft of EN 45680-85 fixture and EN 45680-853 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3489 8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block. 9. Using a torque wrench, tighten the threaded shaft of the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly to 102 Nm (75 lb-ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface. 10. Remove the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly (1) from the cylinder block (2). Cylinder Liner Trimming Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3490 Note: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. Note: Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings. 2. Place the EN 45680-863 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3491 3. Place additional EN 45680-863 metal shaving catch plugs into all remaining cylinder bore sleeves. NOTE: Installing the metal shaving catch plug EN 45680-863 deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure. Note: Installing the metal shaving catch plug EN 45680-863 above the recommended depth will cause damage to the metal shaving catch plug EN 45680-863. 4. Ensure that the EN 45680-863 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Important: Before using EN 45680-861 trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the EN 45680-862 set gage ring (1) should be positioned upward on a flat surface. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3492 Important: Ensure that the EN 45680-862 set gage ring surfaces are clean. 6. Carefully position EN 45680-861 trim tool assembly onto the EN 45680-862 set gage ring. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the EN 45680-861 trim tool assembly height until the blades are worn or damaged 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 N.m (14 lb-ft). 10. Place the EN 45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block. 11. Install the EN 45680-864 4 bolts into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 N.m (15 lb-ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3493 Note: For proper tool operation a drill motor with a 1/2 inch chuck 1-1/8 hp. 7 amps, triple gear reduction and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur. 12. Fasten the drive adapter EN 45680-866 into the drill chuck. Note: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage. 13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-861 trim tool assembly Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place the EN 45680-866 drive adapter and the drill assembly vertically onto the EN 45680-861 drive adapter end of trim tool assembly . Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove the EN 45680-866 drive adapter (1) and the drill assembly from the EN 45680-861 trim tool assembly. 16. Turn OFF the compressed air valve. 17. Remove the EN 45680-861 trim tool assembly from the engine block. 18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-863 metal shaving catch plug. 19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline. 20. Using a light, illuminate the backside of the straight edge. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 3494 21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary. 24. Install the piston and the connecting rod. Refer to Piston, Connecting Rod, and Bearing Installation. 25. Install the oil pan. Refer to Oil Pan Replacement. 26. Install the cylinder head. Refer to Cylinder Head Replacement. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3495 Cylinder Liner: Service and Repair The content of this article reflects the changes identified in TSB 03-06-01-018c Bulletin No.: 03-06-01-018C Date: October 24, 2005 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2002-2005 Chevrolet Cavalier 2004-2006 Chevrolet Classic, Malibu 2005-2006 Chevrolet Cobalt, Cobalt SS 2006 Chevrolet HHR 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Sunfire 2002-2006 Pontiac Grand Am 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Soltice with Ecotec 2.0L, 2.2L or 2.4L 4-Cylinder Engine (VINs P, F, B - RPOs LSJ, L61, LE5) Cylinder Bore Sleeve Removal Note: Be careful not to damage the crankshaft connecting rod journals or reluctor ring. 1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. Important: Use four old cylinder head bolts for the attaching bolts. 2. Install EN 45680-851(2) to the cylinder block while installing the EN 45680-852 (1) through the cylinder bore. Note: Be sure the shoe is flat against the bottom of the cylinder bore sleeve or damage to the EN 45680-852 will occur. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3496 3. Align the shoe (1) of EN 45680-852 to the bottom of the cylinder bore sleeve (117). 4. Hold the threaded shaft upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. Tighten the nut (1) to the bearing (3). 5. Tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 Nm (11 lb ft). Note: Be careful not to damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3497 6. Remove EN 45680-851, EN 45680-852, and the cylinder bore sleeve (117) from the engine block. 7. Loosen the nut (1) in order to remove the cylinder bore sleeve (117). Cylinder Bore Sleeve Installation 1. Place the NEW cylinder bore sleeve (117), P/N 88984129, onto the cylinder block. 2. Install EN 45680-851/EN 45680-853 assembly (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117). Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the EN 45680-851(1). 4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten Tighten the 4 attachment bolts to 15 Nm (11 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3498 5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100). 6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117). 7. Align the pusher block (2) of EN 45680-853 into the groove of EN 45680-851(1). Note: Do not use any air or electric tools to rotate the threaded shaft of the EN 45680-851/EN 45680-853 assembly or damage to the cylinder bore liner will occur. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3499 8. Using a ratchet, rotate the threaded shaft of EN 45680-851/EN 45680-853 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100). 9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 in (1.6 mm) of the cylinder bore sleeve assembly above the surface of the cylinder block. 10. Using a torque wrench, the cylinder bore liner can be completely seated in place when the threaded shaft is torqued to 102 N.m (75 lb-ft). With the liner properly installed, a minimal portion of the sleeve flange will protrude above the block deck surface. 11. Remove the EN 45680-851/EN 45680-853 assembly (1) from the cylinder block (100). Cylinder Sleeve Trimming Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3500 Tools Note:Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot (1). The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN 45680-899) was sent in November, 2004 to affected Chevrolet and Pontiac dealers. The new pilot is white in color and should be installed on EN 45680-861 Trim Tool Assembly. Inspect EN 45680-861 to ensure the correct white pilot is installed. Tools Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3501 The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Refer to the illustration above. Note: After installing the new cylinder bore sleeves into the engine block, trim the excess material from the top area of the cylinder bore liners. It is important that all the material shavings are collected so they do not cause engine damage. 1. Place EN 45680-863 into the cylinder to be trimmed. Position the top of the EN 45680-863 approximately 4.7 mm (3/16 in) below the top surface of the liner. 2. Place additional EN 45680-863s into adjacent cylinders. Note:Installing the EN-45680-863 deeper than the recommended depth will create a decrease in vacuum system performance. Decrease in vacuum system pressure will cause metal shavings to enter the engine and cause engine failure. Note:Installing the catch plug above the recommended depth will cause damage to the plug. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3502 3. Ensure that the EN 45680-863 is 4.7 mm (3/16 in) below the top surface of the sleeve. Important: Before using EN 45680-861 the height of the cutting blades must be set to the manufacturers specifications. The manufacturers specifications indicate that the cylinder bore sleeve top face must be flush to +0.02 mm (0.0008 in) above the deck surface. The recessed area (1) of the set gage ring should be positioned upward and facing the cutting tool. 4. Position EN 45680-862 assembly onto a flat surface. Important: Ensure that the surfaces are clean. 5. Carefully position EN 45680-861 onto the set gage ring. 6. Loosen the shaft collar (2). 7. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the height for the remaining cylinders until the blades are worn to the point of non-compliance or blade replacement has been performed. 8. Holding downward pressure on the collar and inner drive shaft using the trim tool preloader (1), securely tighten the shaft collar screw. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3503 Tighten Tighten the shaft collar screw to 19 Nm (14 lb ft). 9. Place EN 45680-861 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block. 10. Install the 4 EN 45680-864 (2) into the cylinder head bolt holes in the block. Tighten Tighten the bolts progressively to 20 Nm (15 lb ft). 11. Fasten EN 45680-866 (1) into the drill chuck. Note: Ensure there are no kinks in the air feed hose or the vacuum hose. Kinks in the hose may cause metal shavings to exit the cutting tool in any direction, which can cause possible engine damage. 12. Connect a compressed air supply (75-125 psi) (517-862 kpa) to the male quick connect (3) located on EN 45680-861. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings. 13. Place EN 45680-866/drill (1) vertically onto the ball end of EN 45680-861. Do not apply downward force on the drill until the full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete - approximately 10 seconds. 14. Remove EN 45680-866 (1) from the EN 45680-861. 15. Turn off the compressed air valve (2). 16. Remove EN 45680-861 from the engine block. 17. Remove any material shavings that may be found resting on the EN 45680-863. 18. Remove EN 45680-863 and wipe the cylinder bore and surrounding areas free from any powder residue. 19. Proceed to the next cylinder bore sleeve to be trimmed repeating steps 6-14. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 3504 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt First Pass ........................................................................................................ ......................................................................................... 100 Nm (74 ft. lbs.) Final Pass .................. .............................................................................................................................................................. .............................. 75 degrees Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons Piston - Piston Diameter - @14.5 mm up ................................................................................................. 85.967-85.982 mm (3.3845-3.3851 inch) Piston - Piston Pin Bore Diameter ....................................................................................................................... 20.002-20.007 mm (0.07875-0.7877 inch) Piston - Piston Ring Grove Width - Top ....................................................................................................................... 1.23-1.25 mm (0.0484-0.0492 inch) Piston - Piston Ring Grove Width - Second .................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 inch) Piston - Piston Ring Grove Width - Oil Control ........................................................................................................... 2.52-2.54 mm (0.0992-0.1000 inch) Piston - Piston To Bore Clearance ............................................................................................................................ 0.010-0.041 mm (0.0004-0.0016 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Piston Ring End Gap - First Compression Ring ................................................................................................................ 0.20-0.40 mm (0.008-0.016 inch) Piston Ring End Gap - Second Compression Ring ........................................................................................................... 0.35-0.55 mm (0.014-0.022 inch) Piston Ring End Gap - Oil Control Ring - Rails ............................................................................................................... 0.25-0.76 mm (0.010-0.030 inch) Piston Ring to Groove Clearance - First Compression Ring ......................................................................................... 0.04-0.08 mm (0.0015-0.0031 inch) Piston Ring to Groove Clearance - Second Compression Ring ................................................................................. 0.030-0.069 mm (0.0012-0.0027 inch) Piston Ring to Groove Clearance - Oil Control Ring ................................................................................................ 0.090-0.106 mm (0.0035-0.0042 inch) Piston Ring Thickness - First Compression Ring ...................................................................................................... 1.170-1.190 mm (0.0461-0.0469 inch) Piston Ring Thickness - Second Compression Ring ................................................................................................. 1.471-1.490 mm (0.0579-0.0587 inch) Piston Ring Thickness - Oil Control Ring - Rail - Maximum ............................................................................................................ 0.43 mm (0.0169 inch) Piston Ring Thickness - Oil Control Ring - Spacer ................................................................................................... 1.574-1.651 mm (0.0620-0.0650 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3519 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3520 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Camshaft Cover Replacement Removal Procedure 1. Remove the ignition coils. 2. Remove the ground strap and stud. 3. Disconnect the positive crankcase ventilation (PCV) hose from the cam cover. 4. Disconnect the fuel feed pipe from the fuel rail. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 3524 5. Remove the camshaft cover bolts. 6. Remove the camshaft cover. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the camshaft cover and bolts. ^ Tighten the camshaft cover bolts to 10 Nm (89 inch lbs.). 2. Install the ground strap to the camshaft cover. ^ Tighten the ground strap stud to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 3525 3. Install the ignition coils. 4. Connect the fuel feed pipe to the fuel rail. 5. Install the fuel pipe bracket. ^ Tighten the fuel pipe bracket bolt to 10 Nm (89 inch lbs.). 6. Connect the PCV hose to the cam cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 43649 Valve Spring Compressor - J 36017 Valve Guide Seal Remover Removal Procedure 1. Remove the camshaft. 2. Remove the camshaft roller followers. 3. Install the J 43649 to the cylinder head. 4. Remove the spark plugs. 5. Install an air hose adaptor into the spark plug hole. 6. Pressurize the cylinder to 690 kPa (100 psi). 7. Compress the valve spring. 8. Remove the valve spring keepers. 9. Remove the valve spring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3529 10. Using the J 36017, remove the valve seal. Installation Procedure 1. Using the J 36017, install the valve seal. 2. Install the valve spring. 3. Compress the valve spring. 4. Install the valve spring keepers. 5. Remove the air hose adaptor from the spark plug hole. 6. Remove the J 43649 from the cylinder head. 7. Install the spark plugs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3530 8. Install the camshaft roller followers. 9. Install the camshaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3536 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 3537 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 3538 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3541 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3542 The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3543 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3544 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3545 that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3546 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3547 similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3548 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3549 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3550 The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3551 mis-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3552 may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3553 The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3554 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3555 Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3556 may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3557 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the right front fender liner. 2. Important: The drive belt tensioner is a hydraulic tensioner with high initial torque. Release slowly to ensure proper operation. Using an open end wrench, rotate the drive belt tensioner counter clockwise to release the spring tension. 3. Remove the drive belt. Installation Procedure 1. Using an open end wrench, rotate the drive belt tensioner counter clockwise to release the spring tension. 2. Install the drive belt. 3. Install the right front fender liner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner Diagnosis Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 3561 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Supercharger Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the drive belt tensioner bolts. ^ Tighten the drive belt tensioner bolts to 45 Nm (33 ft. lbs.). 3. Install the drive belt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection 1. Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is the engine mount, not the engine or accessories. Install the engine support fixture. 2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the engine mount and creates slight tension on the rubber. 3. Replace the engine mount if the engine mount exhibits any of the following conditions: ^ The hard rubber is covered with heat check cracks. ^ The rubber is separated from the metal plate of the engine mount. ^ The rubber is split through the center of the engine mount. ^ The engine mount itself is leaking fluid. 4. For engine mount replacement, refer to Engine Mount Replacement. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement Engine Mount: Service and Repair Engine Mount Replacement Engine Mount Replacement Removal Procedure 1. Support the engine with a hydraulic floor jack. Use a piece of wood between the jack and the oil pan. 2. Remove the engine mount to intermediate bracket bolts. 3. Remove the engine mount to midrail nuts (4). 4. Remove the engine mount from the engine compartment. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement > Page 3567 1. Place the engine mount onto the midrail and hand start the nuts. 2. Notice: Refer to Fastener Notice in Service Precautions. Tighten the engine mount to midrail nuts (4). ^ Tighten the nuts to 100 Nm (74 ft. lbs.). 3. Important: The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes. Hand start the engine mount to intermediate bracket bolts. 4. Important: The engine mount bracket bolts must be torqued in a mandatory torque sequence as shown. Tighten the engine mount to intermediate bracket bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 5. Remove the hydraulic floor jack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement > Page 3568 Engine Mount: Service and Repair Engine Support Fixture Engine Support Fixture ^ Tools Required SA9105E Engine Support Fixture (3 Bar) - J 43405 Engine Support Fixture Adaptor Installation Procedure 1. Place the engine support fixture long bar (2), from the SA9105E across the engine compartment. 2. Install the engine support fixture legs (3) from the J 43405 on the engine support fixture long bar and center above the engine. 3. Install the engine support fixture hooks (4) and engine support fixture handle to the engine support cross bar. 4. Place the engine support cross bar over the engine support long bar and connect the hooks to the engine lift brackets. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - 1000 RPM ................................................................................................................................... 344.75-551.60 kPa 50-80 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3573 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. ^ Run the engine, and verify low, or no oil pressure on the vehicle gage or light.Listen for a noisy valve train or a knocking noise. ^ Inspect for the following: ^ Oil diluted by moisture or unburned fuel mixtures ^ Improper oil viscosity for the expected temperature ^ Incorrect or malfunctioning oil pressure sender ^ Incorrect or malfunctioning oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil bypass valve ^ Remove the oil pressure sender or another engine block oil gallery plug. ^ Install an oil pressure gage and measure the engine oil pressure. ^ Compare the readings to specifications. ^ If the engine oil pressure is below specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Oil pump-to-engine front cover bolts loose ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure regulator valve ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed ^ Broken lash adjusters Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Unclip the electrical wiring harness from the oil level indicator tube. 3. Lower the vehicle. 4. Remove the oil level indicator tube bolt and unclip the upper wiring harness. 5. Remove the oil level indicator tube. 6. Remove the oil level indicator tube seal. Installation Procedure 1. Install the oil level indicator tube seal. 2. Install the oil level indicator tube. 3. Clip the upper electrical wiring harness to the oil level indicator tube. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the oil level indicator tube bolt. ^ Tighten the oil level indicator tube bolt to 10 Nm (89 inch lbs.). 5. Raise the vehicle. 6. Clip the lower wiring harness. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3581 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3582 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... .............................................................. 4.7L (5.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3585 Engine Oil: Fluid Type Specifications Look for two things: 1. GM4718M Your vehicle's engine requires a special oil meeting GM Standard GM4718M. Oils meeting this standard may be identified as synthetic. However, not all synthetic oils will meet this GM standard. You should look for and use only an oil that meets GM Standard GM4718M. NOTICE: If you use oils that do not have the GM4718M Standard designation, you can cause engine damage not covered by your warranty. 2.SAE 5W-30 As shown in the viscosity chart, SAE 5W-30 is best for your vehicle. However, you can use SAE 10W-30 if it is going to be 0°F (-18°C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this on the oil container, and use only those oils that are identified as meeting GM Standard GM4718M and have the starburst symbol on the front of the oil container. Your vehicle's engine is filled at the factory with a Mobil 1 synthetic oil, which meets all requirements for your vehicle. SUBSTITUTE ENGINE OIL: When adding oil to maintain engine oil level, oil meeting GM Standard GM4718M may not be available. You can add substitute oil designated SAE 5W-30 with the starburst symbol at all temperatures. If temperatures are above 0°F (-18°C), you may substitute SAE 10W-30 with the starburst symbol. Substitute oil not meeting GM Standard GM4718M should not be used for an oil change. ENGINE OIL ADDITIVES Do NOT add engine oil additives. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3586 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Lower the vehicle. 5. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. 6. Loosen the oil filter housing. 7. Remove the tools. 8. Remove the oil filter and housing. 9. Remove the filter from the cap. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3587 1. Install the filter to the housing. 2. Install the oil filter cap with filter. 3. Install the oil filter to the housing. 4. Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Fill the engine with oil. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair Oil Cooler Replacement Removal Procedure 1. Drain the charged air cooling system. 2. Remove the oil pressure sensor (1). 3. Disconnect the oil cooler hoses (2). 4. Remove the oil cooler stud (3) and the oil cooler bolts (4). 5. Remove the oil cooler. Installation Procedure 1. Install the oil cooler. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the oil cooler bolts (4) and stud (3). ^ Tighten the bolts and stud to 22 Nm (16 ft. lbs.). 3. Connect the oil cooler hoses (2). 4. Install the oil pressure sensor (1). ^ Tighten the sensor to 22 Nm (16 ft. lbs.). 5. Fill the charged air cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3595 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Lower the vehicle. 5. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. 6. Loosen the oil filter housing. 7. Remove the tools. 8. Remove the oil filter and housing. 9. Remove the filter from the cap. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3596 1. Install the filter to the housing. 2. Install the oil filter cap with filter. 3. Install the oil filter to the housing. 4. Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. Important: DO NOT use an open end wrench on the hex on top of the oil filter cap. Use a 32 mm (1 1/4 inch) socket with a long extension (1/2 to 3/8 reducer helps if available) and ratchet on the hex on the top of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Fill the engine with oil. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan to Block Bolts .......................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3600 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the engine oil. 3. Remove the engine drive belt. 4. Remove the intercooler pump bracket bolts from the oil pan. 5. Remove the lower AC compressor bolt from the oil pan. 6. Remove the oil pan bolts. 7. Remove the oil pan. Installation Procedure 1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris. 2. Apply a 2 mm bead of RTV, Saturn P/N 21019581, around the perimeter of the oil pan and the oil suction port opening. Do not over apply the RTV. More than a 2 mm bead is not required. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3601 3. Install the oil pan. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts in sequence. ^ Tighten the oil pan bolts to 25 Nm (18 ft. lbs.). 5. Install the AC compressor bolts. 6. Install the intercooler pump bracket bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Install the engine drive belt. 8. Lower the vehicle. 9. Fill the engine oil to the proper level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - 1000 RPM ................................................................................................................................... 344.75-551.60 kPa 50-80 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3612 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. ^ Run the engine, and verify low, or no oil pressure on the vehicle gage or light.Listen for a noisy valve train or a knocking noise. ^ Inspect for the following: ^ Oil diluted by moisture or unburned fuel mixtures ^ Improper oil viscosity for the expected temperature ^ Incorrect or malfunctioning oil pressure sender ^ Incorrect or malfunctioning oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil bypass valve ^ Remove the oil pressure sender or another engine block oil gallery plug. ^ Install an oil pressure gage and measure the engine oil pressure. ^ Compare the readings to specifications. ^ If the engine oil pressure is below specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Oil pump-to-engine front cover bolts loose ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure regulator valve ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed ^ Broken lash adjusters Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3617 Intake Manifold: Specifications Intake Manifold to Cylinder Head Bolt .................................................................................................................................................... 22 Nm (16 ft. lbs.) Intake Manifold to Cylinder Head Nut ..................................................................................................................................................... 22 Nm (16 ft. lbs.) Intake Manifold to Cylinder Head Stud .................................................................................................................................................. 6 Nm (53 inch lbs.) Throttle Body Bolt ................................................................................................................................ ................................................ 10 Nm (89 inch lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3618 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Remove the supercharger. 2. Remove the generator. 3. Drain the charged air cooling system. 4. Disconnect the charged air cooling system inlet and outlet hoses. 5. Remove the charged air coolant pump. 6. Remove the cooling fan assembly. 7. Remove the oil level indicator tube bolt. 8. Remove the electrical connector from the intake manifold. 9. Remove the coolant hoses from the intake manifold. 10. Important: Be sure to remove all fasteners before attempting to remove the intake manifold. Remove the intake manifold nuts and bolts. 11. Remove the intake manifold. 12. Important: The intake manifold gasket is reusable. Only replace the gasket if damage has occurred. Remove the intake manifold gasket. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3619 1. Install the intake manifold gasket. 2. Install the intake manifold. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the intake manifold nuts and bolts. ^ Tighten the intake manifold nuts and bolts to 10 Nm (89 inch lbs.). 4. Install the coolant hoses to the intake manifold. ^ Tighten the hose clamps to 17 Nm (13 ft. lbs.). 5. Connect the electrical connector to the intake manifold. 6. Install the oil level indicator tube and bolt. ^ Tighten the oil level indicator tube bolt to 10 Nm (89 inch lbs.). 7. Reposition the AC compressor and install the bolts. ^ Tighten the bolts to 22 Nm (16 ft. lbs.). 8. Install the cooling fan assembly. 9. Install the charged air coolant pump. 10. Install the generator. 11. Connect the charged air cooling system inlet and outlet hoses. 12. Fill the charged air cooling system. 13. Install the supercharger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement ^ Tools Required J 42067 Rear Main Seal Installer Removal Procedure 1. Remove the transmission. 2. Remove the flywheel. 3. Important: Do not damage the outside diameter of the crankshaft or chamber with any tool. Pry the crankshaft rear oil seal with a flat-bladed tool. Installation Procedure 1. Use the J 42067 and install the seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3624 2. Notice: Refer to Fastener Notice in Service Precautions. Install the flywheel. ^ Tighten the flywheel bolts to 53 Nm (39 ft. lbs.) plus 25 degrees. 3. Install the transmission. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 35268-A Camshaft/Front Main Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Use a flat-bladed tool to remove the seal from the front cover. Installation Procedure 1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover. 2. Install the crankshaft balancer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 43649 Valve Spring Compressor - J 36017 Valve Guide Seal Remover Removal Procedure 1. Remove the camshaft. 2. Remove the camshaft roller followers. 3. Install the J 43649 to the cylinder head. 4. Remove the spark plugs. 5. Install an air hose adaptor into the spark plug hole. 6. Pressurize the cylinder to 690 kPa (100 psi). 7. Compress the valve spring. 8. Remove the valve spring keepers. 9. Remove the valve spring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3631 10. Using the J 36017, remove the valve seal. Installation Procedure 1. Using the J 36017, install the valve seal. 2. Install the valve spring. 3. Compress the valve spring. 4. Install the valve spring keepers. 5. Remove the air hose adaptor from the spark plug hole. 6. Remove the J 43649 from the cylinder head. 7. Install the spark plugs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3632 8. Install the camshaft roller followers. 9. Install the camshaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair Balance Shaft: Service and Repair Crankshaft Balancer Replacement ^ Tools Required J 38122-A Harmonic Balancer Holder Removal Procedure 1. Remove the engine drive belt. 2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. 3. Remove the crankshaft balancer bolt. Discard the bolt. 4. Remove the crankshaft balancer. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Page 3644 1. Install the crankshaft balancer. 2. Install a NEW crankshaft balancer bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Use J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. ^ Tighten the bolt to 100 Nm (74 ft. lbs.) plus 75 degrees. 4. Install the engine drive belt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain, Sprockets, and/or Tensioner Replacement ^ Tools Required J 45027 Tensioner Tool Removal Procedure 1. Remove the camshaft cover. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine front cover. 4. Lower the vehicle. 5. Important: To rotate the camshaft, use a 24 mm open-end wrench on the camshaft flats. Camshaft should be rotated in a clockwise direction only, facing camshaft sprockets from the passenger side of the vehicle. Locate the No. 1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove the spark plugs. This will ease the rotation effort. 6. Remove the timing chain tensioner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3648 7. Remove the fixed timing chain guide access plug. 8. Remove the fixed timing chain guide. 9. Remove the upper timing chain guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3649 10. Use a 24 mm wrench to hold the camshafts from turning. 11. Remove the exhaust camshaft sprocket bolt and discard. 12. Remove the exhaust camshaft sprocket. 13. Remove the timing chain tensioner guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3650 14. Remove the intake camshaft sprocket bolt and discard. 15. Remove the intake camshaft sprocket. 16. Remove the timing chain through the top of the cylinder head. 17. Remove the crankshaft sprocket. 18. Remove the oil nozzle and bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3651 19. Remove the balance shaft drive chain tensioner. 20. Remove the adjustable balance shaft chain guide. 21. Remove the small balance shaft drive chain guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3652 22. Remove the upper balance shaft drive chain guide. 23. Important: It may ease removal of the balance shaft drive chain to get all of the slack in the chain between the crankshaft and water pump sprockets. Remove the balance shaft drive chain. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise. Install the upper balance shaft chain guide. ^ Tighten the upper balance shaft chain guide bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3653 2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. Use the following procedure to line up the links with the sprockets:Orient the chain so that the copper colored and chrome links are visible. 1. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket. 2. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 5 o'clock position on the crank sprocket). 3. Place the chain (3) on the water pump drive sprocket (alignment is not critical). 4. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket. 3. Install the small balance shaft chain guide. 4. Tighten the balance shaft chain guide bolts. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). 5. Install the adjustable balance shaft drive chain guide. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3654 6. Turn the tensioner plunger 90 degrees in its bore and compress the plunger until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger. 7. Install the timing chain tensioner. 8. Tighten the chain tensioner bolts. ^ Tighten the chain tensioner bolts to 10 Nm (89 inch lbs.). 9. Remove the paper clip from the balance shaft drive chain tensioner. 10. Install the oil nozzle and bolt. ^ Tighten the oil nozzle bolt to 10 Nm (89 inch lbs.). 11. Install the crankshaft sprocket with timing mark at the 5 o'clock position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3655 12. Lower the timing chain through the opening in the top of the cylinder head. Carefully ensure that the chain goes around both sides of the cylinder block bosses (1, 2). 13. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position. 14. Important: Always install NEW sprocket bolts. Hand tighten a NEW intake camshaft sprocket bolt. 15. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark. 16. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond. 17. Install the timing chain tensioner guide through the opening in the top of the cylinder head. ^ Tighten the timing chain tensioner guide bolt to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3656 18. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position. 19. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft. 20. Important: Always install NEW sprocket bolts. Hand tighten the NEW exhaust camshaft sprocket bolt. 21. Install the fixed timing chain guide. ^ Tighten the fixed timing chain bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3657 22. Apply sealant, Saturn P/N 21485277 compound to thread and install the timing chain guide bolt access hole plug. ^ Tighten the chain guide plug to 90 Nm (59 ft. lbs.). 23. Install the timing chain upper guide. ^ Tighten the timing chain upper guide bolts to 10 Nm (89 inch lbs.). 24. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner. 25. Measure the timing chain tensioner assembly from end to end.A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 inch) (a) from end to end. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3658 26. If the timing chain tensioner is not in the compressed state, perform the following steps: 1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. 2. Install the J 45027-2 (2) into a vise. 3. Install the notch end of the piston assembly into the J 45027-2 (2). 4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston. 27. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth. 28. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again. 29. At this point the tensioner should measure approximately 72 mm (2.83 inch) (a) from end to end. If the tensioner does not read 72 mm (2.83 inch) (a) from end to end repeat steps 29.1 through 29.4. 30. Install the timing chain tensioner. ^ Tighten the timing chain tensioner to 75 Nm (55 ft. lbs.). 31. Use a suitable tool with a rubber tip on the end. Feed the tool down through the camshaft drive chain to rest on the timing chain. Then give a sharp Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3659 jolt diagonally downwards to release the tensioner. 32. Use a 24 mm wrench to hold the camshaft. ^ Tighten the NEW camshaft bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 33. Install the camshaft cover. 34. Raise the vehicle. Refer to Vehicle Lifting. 35. Install the engine front cover. 36. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair Timing Chain Tensioner: Service and Repair Timing Chain, Sprockets, and/or Tensioner Replacement ^ Tools Required J 45027 Tensioner Tool Removal Procedure 1. Remove the camshaft cover. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the engine front cover. 4. Lower the vehicle. 5. Important: To rotate the camshaft, use a 24 mm open-end wrench on the camshaft flats. Camshaft should be rotated in a clockwise direction only, facing camshaft sprockets from the passenger side of the vehicle. Locate the No. 1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove the spark plugs. This will ease the rotation effort. 6. Remove the timing chain tensioner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3663 7. Remove the fixed timing chain guide access plug. 8. Remove the fixed timing chain guide. 9. Remove the upper timing chain guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3664 10. Use a 24 mm wrench to hold the camshafts from turning. 11. Remove the exhaust camshaft sprocket bolt and discard. 12. Remove the exhaust camshaft sprocket. 13. Remove the timing chain tensioner guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3665 14. Remove the intake camshaft sprocket bolt and discard. 15. Remove the intake camshaft sprocket. 16. Remove the timing chain through the top of the cylinder head. 17. Remove the crankshaft sprocket. 18. Remove the oil nozzle and bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3666 19. Remove the balance shaft drive chain tensioner. 20. Remove the adjustable balance shaft chain guide. 21. Remove the small balance shaft drive chain guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3667 22. Remove the upper balance shaft drive chain guide. 23. Important: It may ease removal of the balance shaft drive chain to get all of the slack in the chain between the crankshaft and water pump sprockets. Remove the balance shaft drive chain. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise. Install the upper balance shaft chain guide. ^ Tighten the upper balance shaft chain guide bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3668 2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. Use the following procedure to line up the links with the sprockets:Orient the chain so that the copper colored and chrome links are visible. 1. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket. 2. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 5 o'clock position on the crank sprocket). 3. Place the chain (3) on the water pump drive sprocket (alignment is not critical). 4. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket. 3. Install the small balance shaft chain guide. 4. Tighten the balance shaft chain guide bolts. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). 5. Install the adjustable balance shaft drive chain guide. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3669 6. Turn the tensioner plunger 90 degrees in its bore and compress the plunger until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger. 7. Install the timing chain tensioner. 8. Tighten the chain tensioner bolts. ^ Tighten the chain tensioner bolts to 10 Nm (89 inch lbs.). 9. Remove the paper clip from the balance shaft drive chain tensioner. 10. Install the oil nozzle and bolt. ^ Tighten the oil nozzle bolt to 10 Nm (89 inch lbs.). 11. Install the crankshaft sprocket with timing mark at the 5 o'clock position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3670 12. Lower the timing chain through the opening in the top of the cylinder head. Carefully ensure that the chain goes around both sides of the cylinder block bosses (1, 2). 13. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position. 14. Important: Always install NEW sprocket bolts. Hand tighten a NEW intake camshaft sprocket bolt. 15. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark. 16. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond. 17. Install the timing chain tensioner guide through the opening in the top of the cylinder head. ^ Tighten the timing chain tensioner guide bolt to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3671 18. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position. 19. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft. 20. Important: Always install NEW sprocket bolts. Hand tighten the NEW exhaust camshaft sprocket bolt. 21. Install the fixed timing chain guide. ^ Tighten the fixed timing chain bolts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3672 22. Apply sealant, Saturn P/N 21485277 compound to thread and install the timing chain guide bolt access hole plug. ^ Tighten the chain guide plug to 90 Nm (59 ft. lbs.). 23. Install the timing chain upper guide. ^ Tighten the timing chain upper guide bolts to 10 Nm (89 inch lbs.). 24. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner. 25. Measure the timing chain tensioner assembly from end to end.A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 inch) (a) from end to end. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3673 26. If the timing chain tensioner is not in the compressed state, perform the following steps: 1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. 2. Install the J 45027-2 (2) into a vise. 3. Install the notch end of the piston assembly into the J 45027-2 (2). 4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston. 27. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth. 28. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again. 29. At this point the tensioner should measure approximately 72 mm (2.83 inch) (a) from end to end. If the tensioner does not read 72 mm (2.83 inch) (a) from end to end repeat steps 29.1 through 29.4. 30. Install the timing chain tensioner. ^ Tighten the timing chain tensioner to 75 Nm (55 ft. lbs.). 31. Use a suitable tool with a rubber tip on the end. Feed the tool down through the camshaft drive chain to rest on the timing chain. Then give a sharp Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 3674 jolt diagonally downwards to release the tensioner. 32. Use a 24 mm wrench to hold the camshaft. ^ Tighten the NEW camshaft bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 33. Install the camshaft cover. 34. Raise the vehicle. Refer to Vehicle Lifting. 35. Install the engine front cover. 36. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Front Cover to Block Bolt ..................................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3681 Timing Cover: Service and Repair Engine Front Cover Replacement 1. Remove the crankcase balancer. 2. Remove the drive belt tensioner. 3. Remove the idler pulley. 4. Remove the engine front cover to water pump bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3682 5. Remove the remaining engine front cover bolts. 6. Remove the engine front cover. 7. If the engine front cover gasket is damaged, remove the front engine mount. Installation Procedure 1. If removed, install a new engine front cover gasket. 2. Install the front engine mount. 3. Install the engine front cover. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the engine front cover bolts. ^ Tighten the engine front cover bolts to 25 Nm (18 ft. lbs.). 5. Install the water pump bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3683 ^ Tighten the water pump bolt to 25 Nm (18 ft. lbs.). 6. Install the idler pulley. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Install the drive belt tensioner. 8. Install the drive belt tensioner bolts. ^ Tighten the drive belt tensioner bolts to 45 Nm (33 ft. lbs.). 9. Install the crankcase balancer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3690 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3691 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cracking times. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3692 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3693 Steps 7 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: Customer Interest Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 3702 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: All Technical Service Bulletins Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 3708 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3709 Idle Speed: By Symptom Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3710 Disclaimer Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3711 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 3712 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Intake Duct Replacement AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front tire and wheel. 2. Remove the left front fender liner. 3. Remove the air cleaner intake duct assembly push-in fasteners. 4. Remove the air cleaner intake duct assembly bolt. 5. Remove the intake duct assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the intake duct assembly. 2. Install the intake duct assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb ft). 3. Install the intake duct assembly push in fasteners. 4. Install the left front fender liner. 5. Install the left front tire and wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 3718 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly air duct at the outlet duct clamp 1. 2. Loosen the outlet duct clamp 2 at the throttle body. 3. Remove the air outlet duct. INSTALLATION PROCEDURE 1. Install the air outlet duct. 2. Install the air outlet duct clamps 1 and 2. 3. Tighten the air outlet duct clamps 1 and 2. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 3719 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3728 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3734 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3735 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Loosen the air cleaner cover screws (1). 3. Remove the air cleaner cover (2). 4. Remove the air cleaner filter from the air cleaner housing (3). INSTALLATION PROCEDURE 1. Install the air cleaner filter into the air cleaner housing. 2. Install the air cleaner cover to the air cleaner housing. 3. Install the air cleaner housing cover screws (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3736 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air cleaner housing screws to 3 N.m (27 lb in). 4. Install the air cleaner assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3742 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3743 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... .................................... 25 - 30 Nm (18.4 - 22.1 lb ft) Spark Plug Gap ................................................ ............................................................................................................................................... 1 mm (0.04 in) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3750 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................... GM P/N 12787099 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3751 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3752 - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3753 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coils. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT coat the spark plugs with anti-seize compound. Over torquing could occur and damage to the cylinder head threads may Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3754 result. Tighten the spark plugs to 20 N.m (15 lb ft). 3. Install the ignition coils. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70 percent of the highest. No cylinder reading should be less than 689 kPa (100 psi) Compression Ratio ................................................................. ...................................................................................................................................... 9.5:01 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3758 Compression Check: Testing and Inspection Engine Compression Test Perform the following steps to conduct a compression test. 1. Conduct the following steps to check cylinder compression. 1. Engine should be at room temperature. 2. Disconnect wiring from the ignition module. 3. Remove the spark plugs. 4. Throttle body valve should be wide open. 5. Battery should be at or near full charge. 2. For each cylinder, crank engine through 4 compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal. Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings. Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves. Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately 3 squirts from a plunger-type oiler. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ..................................................... 25 Nm (18 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > After-Run Coolant Pump > Component Information > Diagrams After Cooling Pump Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3770 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3771 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3772 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3773 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ................................................... 7.4 quarts (7.0 liter) Intercooler System Capacity ........................... ........................................................................................................................................ 2.0 quarts (1.9 liter) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3776 Coolant: Fluid Type Specifications ENGINE COOLANT AND INTERCOOLER SYSTEM COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement Coolant Reservoir: Service and Repair Surge Tank Replacement Surge Tank Replacement ^ Tools Required J 38185 Hose Clamp Pliers - SA9111E Constant Force Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp using J 38185. 3. Remove the surge tank inlet hose from the surge tank. 4. Remove the underhood junction block bracket nuts (1, 2). 5. Remove the underhood junction block bracket bolt (3). 6. Lift the underhood junction block bracket and position away from the surge tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3784 7. Remove the surge tank nut. Lift the surge tank and reposition the surge tank outlet hose clamp using SA9111E. 8. Remove the surge tank outlet hose. 9. Disconnect the coolant level sensor electrical connector. 10. Remove the surge tank. Installation Procedure 1. Install the surge tank. 2. Connect the coolant level sensor electrical connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3785 3. With the surge tank raised, install the surge tank outlet hose. 4. Reposition the hose clamp using J 38185 to secure the hose. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the surge tank nut. ^ Tighten the nut to 10 Nm (89 inch lbs.). 6. Set the underhood junction block bracket into position. 7. Install the underhood junction block bracket nuts (1, 2). ^ Tighten the nuts to 10 Nm (88 inch lbs.). 8. Install the underhood junction block bracket bolt (3). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3786 9. Install the surge tank inlet hose to the surge tank. 10. Reposition the hose clamp using J 38185 to secure the hose. 11. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3787 Coolant Reservoir: Service and Repair Surge Tank Hose/Pipe Replacement - Inlet Surge Tank Hose/Pipe Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Remove the surge tank cap. 2. Reposition the surge tank inlet hose clamp using J 38185. 3. Remove the surge tank inlet hose from the surge tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3788 4. Unclip the surge tank inlet hose from the underhood junction block bracket. 5. Remove the air cleaner outlet resonator. 6. Unclip the surge tank inlet hose from the fuel rail. 7. Reposition the surge tank inlet hose clamp using J 38185. 8. Remove the surge tank inlet hose from the engine. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3789 1. Install the surge tank inlet hose to the engine. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Clip the surge tank inlet hose to the fuel rail. 4. Install the air cleaner outlet resonator. 5. Clip the surge tank inlet hose to the underhood junction block bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3790 6. Install the surge tank inlet hose to the surge tank. 7. Reposition the hose clamp to secure the hose using J 38185. 8. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3791 Coolant Reservoir: Service and Repair Surge Tank Hose/Pipe Replacement - Outlet Surge Tank Hose/Pipe Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the underhood electrical center. 3. Reposition the surge tank outlet hose clamp at the engine using J 38185. 4. Remove the surge tank outlet hose from the engine. 5. Reposition the surge tank inlet hose clamp using J 38185. 6. Remove the surge tank inlet hose from the surge tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3792 7. Remove surge tank nut. 8. Lift surge tank and reposition the surge tank outlet hose clamp using J 38185. 9. Remove surge tank outlet hose. Installation Procedure 1. Route the surge tank outlet hose and install the surge tank outlet hose to the engine. 2. Reposition the hose clamp at the engine to secure the hose using J 38185. 3. With the surge tank raised, install the surge tank outlet hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3793 4. Reposition the hose clamp to secure the hose using J 38185. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the surge tank nut. ^ Tighten the surge tank nut to 10 Nm (89 inch lbs.). 6. Install the underhood electrical center. 7. Install the surge tank inlet hose to the surge tank. 8. Reposition the hose clamp using J 38185 to secure the hose. 9. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Cooling Fan Motors (LSJ) Cooling Fan Motors (LSJ) 1 - Cooling Fan 1 2 - Cooling Fan 2 3 - Radiator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3798 Radiator Cooling Fan Motor: Diagrams Engine Cooling Fan - 1 (LSJ) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3799 Engine Cooling Fan - 2 (LSJ) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3800 Radiator Cooling Fan Motor: Service and Repair Cooling Fan and Shroud Replacement (2.0L (LSJ) Removal Procedure 1. Disconnect the cooling fan electrical connectors. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3801 4. Remove the air dam push-in retainers. 5. Remove the air dam. 6. Remove the right engine splash shield to radiator mount push-in retainer. 7. Remove the left engine splash shield to radiator mount push-in retainer. 8. Remove the charge air cooler radiator. 9. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3802 10. Tilt the radiator and condenser forward in the vehicle. 11. Remove the cooling fan assembly from the vehicle. Installation Procedure 1. Install the cooling fan assembly into the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3803 2. Restore the radiator and condenser to the original position. 3. Install the charge air cooler radiator. 4. Verify that the upper radiator mounts are installed in the vehicle. 5. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3804 6. Notice: Refer to Fastener Notice in Service Precautions. Install the lower radiator mounts, brackets, and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Install the right engine splash shield to radiator mount push-in retainer. 8. Install the left engine splash shield to radiator mount push-in retainer. 9. Install the air dam and the push-in retainers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 3805 10. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator. 11. Lower the vehicle. 12. Connect the cooling fan electrical connectors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3810 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3811 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3812 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3813 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Fan Shroud Replacement Removal Procedure 1. Remove the cooling fan assembly from the vehicle. 2. Scribe the position of each of the cooling fan blades on the cooling fan motor shafts. 3. Remove the cooling fan blade retaining clips and discard. 4. Remove the cooling fan blades. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 3817 5. Remove the cooling fan motor bolts and remove the cooling fan motors. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the cooling fan motors and bolts. ^ Tighten the bolts to 8 Nm (70 inch lbs.). 2. Align the scribe marks on the cooling fan blades and motor shafts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 3818 3. Install the cooling fan blades. 4. Install new retaining clips to the cooling fan blades. 5. Install the cooling fan assembly into the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3823 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3824 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the body control module (BCM) from the vehicle. 2. Remove the front floor console left side extension panel. 3. Pull back the carpet at the bottom of the left instrument panel (I/P) center support bracket and remove the left I/P center support bracket nuts. 4. Remove the left I/P center support bracket. 5. Remove the accelerator control pedal from the front of the dash and position out of the way. 6. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts. 7. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage it from the HVAC module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3827 8. Remove the heater core cover heat stakes with a small chisel. 9. Loosen the nut that is behind the fuel line bracket and remove the stud from the dash panel at the heater hoses. 10. Pull the heater core cover down just enough to clear the locating pins from the HVAC module. Slide the heater core cover rearward until the drain tube clears the front of dash. Slide the heater core cover down, rearward, and to the right to remove. IMPORTANT: Make certain that all of the heater core cover screws are removed before attempting to remove the heater core cover. INSTALLATION PROCEDURE 1. Install a new drain tube seal onto the drain tube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3828 2. Install the heater core cover from the right side. Slide up and forward into position. Align the drain tube with the hole in the front of dash. Raise the heater core cover into position while aligning holes with the locating pins from the HVAC module. IMPORTANT: Spraying the heater core seal and the dashmat with a soap and water mixture will ease installation. 3. Cut the sound insulator at the cowl near the center screw (1) approximately 76 mm (3 in) and fold the sound insulator back to ease in installation of the screw.Ensure the sound insulator is positioned back after the screws are tightened. 4. Install the heater core cover screws. IMPORTANT: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the heater core cover screws to 1.8 N.m (15 lb in). 5. Install the stud into the dash panel at the heater hoses and tighten the nut that is behind the fuel line bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3829 6. Align the center floor duct with the HVAC module. 7. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module. 8. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts. 9. Slide the center floor outlet duct down into position in the floor ducts. 10. Install the accelerator control pedal. 11. Pull back the carpet and place the left center support bracket into position. 12. Install the left center support bracket nuts. Tighten the left center support bracket nuts to 10 N.m (88 lb in). 13. Install the left side front floor console extension panel. 14. Install the BCM to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3830 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED SA9111E Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Place a drain pan under the water pump drain port. 4. Loosen the water pump drain bolt and drain the coolant from the water pump. 5. Close and tighten the water pump drain bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the water pump drain bolt to 10 N.m (88 lb in). 6. Lower the vehicle. 7. Reposition the heater outlet hose clamp at the heater core using SA9111E. 8. Remove the heater outlet hose from the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3831 9. Reposition the heater inlet hose clamp at the heater core using SA9111E. 10. Remove the heater inlet hose from the heater core. 11. Remove the heater core cover. 12. Remove the heater core. INSTALLATION PROCEDURE 1. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 3832 2. Install the heater core into the HVAC module. 3. Install the heater core cover. 4. Install the heater outlet hose to the heater core. 5. Install the hose clamp to secure the hose using SA9111E. 6. Install the heater inlet hose to the heater core. 7. Install the hose clamp to secure the hose using SA9111E. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Remove the surge tank cap. 2. Slide a drain pan under the front of the dashboard under the heater inlet hose. 3. Reposition the heater inlet hose clamp at the heater core using J 38185. 4. Remove the heater inlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 3837 5. Reposition the heater inlet hose clamp at the engine using J 38185. 6. Remove the heater inlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater inlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 3838 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the surge tank cap. CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 2. Place a drain pan under the heater hoses near the front of the dash. 3. Remove the dash panel exterior sound barrier. 4. Reposition the heater outlet hose clamp at the heater core using J 38185. 5. Remove the heater outlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 3839 6. Reposition the hose heater outlet hose clamp at the engine using J 38185. 7. Remove the heater outlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater outlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 3840 7. Install the dash panel exterior sound barrier. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the right side lower radiator mount. 3. Remove the radiator drain cock. Installation Procedure 1. Install the radiator drain cock. Tighten the radiator drain cock by hand only. 2. Lower the vehicle. 3. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet (2.0L (LSJ) ^ Tools Required SA9111E Constant Force Clamp Pliers Removal Procedure 1. Partially remove the splash shields from the right fender liner to gain access to the drain cock. 2. Partially drain the cooling system. 3. Lower the vehicle. 4. Reposition the radiator inlet hose clamp at the radiator using SA9111E. 5. Remove the radiator inlet hose from the radiator. 6. Reposition the radiator inlet hose clamp at the engine using SA9111E. 7. Remove the radiator inlet hose from the engine. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3849 1. Install the radiator inlet hose to the radiator. 2. Reposition the radiator inlet hose clamp to secure the hose using SA9111E. 3. Install the radiator inlet hose to the engine. 4. Reposition the radiator inlet hose clamp to secure the hose using SA9111E. 5. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3850 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet (2.0L (LSJ) ^ Tools Required SA9111E Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Lower the vehicle. 3. Remove the air intake duct. 4. Remove the fan shroud. 5. Reposition the radiator outlet hose clamp at the radiator using SA9111E. 6. Remove the radiator outlet hose from the radiator. 7. Remove the underhood electrical center. 8. Reposition the radiator outlet hose clamp at the engine using SA9111E. 9. Remove the radiator outlet hose from the engine. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 3851 1. Install the radiator outlet hose to the radiator. 2. Reposition the radiator outlet hose clamp to secure the hose using SA9111E. 3. Install the underhood electrical center. 4. Install the radiator outlet hose to the engine. 5. Reposition the radiator outlet hose clamp to secure the hose using SA9111E. 6. Install the fan shroud. 7. Install the air intake duct. 8. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3860 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3861 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3862 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3863 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Testing and Inspection Supercharger Coolant Pump: Testing and Inspection SUPERCHARGER INTERCOOLER RELAY DIAGNOSIS CIRCUIT DESCRIPTION The supercharger (SC) intercooler coolant relay is a normally open relay. The relay armature is held in the open position by spring tension. Ignition 1 voltage is supplied directly to the relay coil and to the armature contact, when the ignition is ON, or the engine is running. The powertrain control module (PCM) supplies the ground path to the relay coil control circuit, via an internal integrated circuit called an output driver module (ODM). When the engine is running, the PCM commands the relay ON, and the relay coil creates an electromagnetic field. This electromagnetic field overcomes the spring tension and pulls the armature contact into the stationary contact of the relay load circuit. The closing of the relay contacts allows current to flow from the battery to the SC intercooler coolant pump. When the ignition switch is turned to the OFF position, power is interrupted to the output driver module in the PCM, and the relay electromagnetic field collapses. This allows the spring tension to separate the relay armature contact from the relay load circuit contact, which interrupts current flow to the SC intercooler coolant pump. The SC intercooler coolant relay diagnosis is used to diagnose the load circuit supply voltage, the relay contacts, the relay load circuit which includes the SC intercooler coolant pump, and the ground for the SC intercooler coolant pump. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Testing and Inspection > Page 3867 Steps 1 - 9 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Testing and Inspection > Page 3868 Steps 10 - 15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet Supercharger Coolant Pump: Service and Repair Auxiliary Water Pump Hose Replacement - Inlet Auxiliary Water Pump Hose Replacement - Inlet ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler pump. 3. Remove the auxiliary water pump inlet hose from the charge air cooler pump. 4. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator. 5. Remove the auxiliary water pump inlet hose from the charge air cooler radiator. Installation Procedure 1. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 2. Install the auxiliary water pump inlet hose to the charge air cooler radiator. 3. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 4. Install the auxiliary water pump inlet hose to the charge air cooler pump. 5. Lower the vehicle. 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 3871 Supercharger Coolant Pump: Service and Repair Auxiliary Water Pump Hose Replacement Outlet Auxiliary Water Pump Hose Replacement - Outlet ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose at the charge air cooler pump. 3. Remove the outlet hose from the charge air cooler pump. 4. Lower the vehicle. 5. Using the GE-47622, compress the clamp at the auxiliary water pump outlet hose at the intercooler. 6. Remove the outlet hose from the charge air cooler radiator. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 3872 1. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose to secure the hose. 2. Install the outlet hose to the intercooler. 3. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose to secure the hose. 4. Install the outlet hose to the charge air cooler pump. 5. Lower the vehicle. 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 3873 Supercharger Coolant Pump: Service and Repair Coolant Pump Replacement - Charge Air Cooler Coolant Pump Replacement - Charge Air Cooler ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the charge air cooling system. 2. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler pump. 3. Remove the auxiliary water pump inlet hose from the charge air cooler pump. 4. Using the GE-47622, compress the auxiliary water pump outlet hose clamp at the charge air cooler pump. 5. Remove the auxiliary water pump outlet hose from the charge air cooler pump. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 3874 6. Disconnect the charge air cooler pump electrical connector. 7. Remove the charge air cooler pump mounting clamp bolts. 8. Remove the charge air cooler pump. Installation Procedure 1. Install the charge air cooler pump. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the mounting clamp bolts to the charge air cooler pump. ^ Tighten the bolts to 10 Nm (88 inch lbs.). 3. Connect the charge air cooler pump electrical connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 3875 4. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 5. Install the auxiliary water pump inlet hose to the charge air cooler pump. 6. Using the GE-47622, compress the auxiliary water pump outlet hose clamp to secure the hose. 7. Install the auxiliary water pump outlet hose to the charge air cooler pump. 8. Lower the vehicle. 9. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Thermostat: Customer Interest Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Bulletin No.: 05-06-04-038D Date: April 13, 2006 TECHNICAL Subject: 2.0L LSJ Engine SES Lamp Illuminated with DTC P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" Set (Reprogram PCM) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with Supercharged 2.0L Four-Cylinder Engine (VIN P - RPO LSJ) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 05-06-04-038C (Section 06 - Engine). Condition Some customers may comment that the Service Engine Soon (SES) lamp is illuminated. Diagnostic Trouble Code (DTC) P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" may be set. Cause Under certain ambient engine temperature conditions, the thermostatically controlled engine coolant temperature may not reach the calibrated threshold in the allotted time frame that is programmed in the PCM. Correction Follow the steps outlined in the "Service Procedure" section of this bulletin to repair a false DTC P0128. Service Procedure Verify operation of the thermostat and cooling system. Refer to "DTC P0128" diagnostic in published Service Information. Before replacing the engine coolant thermostat and/or updating PCM calibration for repairing a false DTC P0128. Perform the following service procedures: 1. Observe the coolant temperature within the P0128 Freeze Frame. ^ If the engine coolant temperature is greater than 70.25°C (158.25°F) with DTC P0128, the PCM needs the updated calibration. Do not replace the engine coolant thermostat. ^ If the engine coolant temperature is less than 70.25°C (158.25°F) with DTC P0128, replace only the engine coolant thermostat. Important: Chevrolet Dealers: The PCM calibration is available to dealerships as part of TIS2000 incremental satellite update version 4.0, which was broadcast to dealers in April, 2006 or later. For the dealerships that use CDs, they were mailed out April, 2006 or later. Important: Saturn Retailers: Before installing the new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 4.0 2006 or later. Important: While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures. Important: Technician must select the "Reprogram" option in order to reprogram the PCM. 2. Reprogram the PCM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0128 concern. Refer to "Service Programming System (SPS)" in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 3884 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Thermostat: All Technical Service Bulletins Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Bulletin No.: 05-06-04-038D Date: April 13, 2006 TECHNICAL Subject: 2.0L LSJ Engine SES Lamp Illuminated with DTC P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" Set (Reprogram PCM) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with Supercharged 2.0L Four-Cylinder Engine (VIN P - RPO LSJ) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 05-06-04-038C (Section 06 - Engine). Condition Some customers may comment that the Service Engine Soon (SES) lamp is illuminated. Diagnostic Trouble Code (DTC) P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" may be set. Cause Under certain ambient engine temperature conditions, the thermostatically controlled engine coolant temperature may not reach the calibrated threshold in the allotted time frame that is programmed in the PCM. Correction Follow the steps outlined in the "Service Procedure" section of this bulletin to repair a false DTC P0128. Service Procedure Verify operation of the thermostat and cooling system. Refer to "DTC P0128" diagnostic in published Service Information. Before replacing the engine coolant thermostat and/or updating PCM calibration for repairing a false DTC P0128. Perform the following service procedures: 1. Observe the coolant temperature within the P0128 Freeze Frame. ^ If the engine coolant temperature is greater than 70.25°C (158.25°F) with DTC P0128, the PCM needs the updated calibration. Do not replace the engine coolant thermostat. ^ If the engine coolant temperature is less than 70.25°C (158.25°F) with DTC P0128, replace only the engine coolant thermostat. Important: Chevrolet Dealers: The PCM calibration is available to dealerships as part of TIS2000 incremental satellite update version 4.0, which was broadcast to dealers in April, 2006 or later. For the dealerships that use CDs, they were mailed out April, 2006 or later. Important: Saturn Retailers: Before installing the new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 4.0 2006 or later. Important: While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures. Important: Technician must select the "Reprogram" option in order to reprogram the PCM. 2. Reprogram the PCM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0128 concern. Refer to "Service Programming System (SPS)" in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 3890 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Page 3891 Thermostat: Service and Repair Thermostat Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the bolts that secure the thermostat housing to the water pump feed pipe. 3. Remove the feed pipe. 4. Remove the thermostat and retaining sleeve, noting the orientation for installation. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Page 3892 1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot. 2. Important: Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump. Install the feed pipe that connects the thermostat housing to the water pump. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt that secures the water pump feed pipe. ^ Tighten the bolt to 10 Nm (18 inch lbs.). 4. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ..................................................... 25 Nm (18 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension Technical Service Bulletin # 08020 Date: 100113 Campaign - Catalytic Converter Warranty Extension SPECIAL COVERAGE Bulletin No.: 08020 Date: January 13, 2010 Subject: 08020 - SPECIAL COVERAGE ADJUSTMENT - EXTENDED CATALYTIC CONVERTER WARRANTY COVERAGE Models: 2004-2007 SATURN ION RED LINE 2005-2007 CHEVROLET COBALT SS EQUIPPED WITH 2.0L 4-CYLINDER (RPO LSJ) ENGINE Condition Some customers of 2004-07 model year Saturn ION Red Line; and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, may comment on illumination of the malfunction indicator lamp (MAL) and/or lack of engine power. This may be caused by failure of the catalytic converter. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers/retailers are to replace the catalytic converter. The repairs will be made at no charge to the customer. Customers should not be charged for performing a system check when it is determined that the catalytic converter is not the cause of the customer complaint. Labor code T5725 is provided to submit claims for such system checks. Any additional necessary diagnosis and repairs that are not related to the catalytic converter are NOT covered by this special coverage. The customer should be informed that any further service that is not covered by the new vehicle warranty will not be covered by this policy. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 14, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 14, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-07 model year Saturn ION and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, and built within the following VIN breakpoints: Important Dealers/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverages are displayed in the Applicable Warranties section. Parts Information GM: Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO). Saturn US Only: Due to the limited number of affected vehicles, Saturn will not be doing a pre-shipment of parts. Retailers should order parts as needed from Saturn Service Parts Operations (SSPO). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3905 Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Service Procedure The purpose of this field action bulletin is to determine if it is necessary to replace the catalytic converter on certain 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine. The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to Strategy Based Diagnosis in SI. Determine the condition of the catalytic converter. Refer to Symptom - Engine Exhaust and Restricted Exhaust in SI. - If diagnosis indicates that the catalytic converter must be replaced, replace the Catalytic Converter. Refer to Catalytic Converter Replacement in SI. - If diagnosis indicates that the catalytic converter does NOT require replacement, determine the cause of the customer-reported exhaust concern using the diagnostic service information in SI. Diagnostic time and service repairs for exhaust system components other than the catalytic converter are NOT covered by this field action. Diagnostic time and service repair work for exhaust system components other than the catalytic converter must be billed under warranty or customer pay. Customer Reimbursement 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For GM US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3906 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to replace the catalytic converter are to be submitted to the dealer prior to or by January 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for this condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form is included with the customer letter. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers/retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter January 2010 Dear General Motors Customer: As the owner of a 2004-07 model year Saturn ION Red Line or 2005-07 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with a 2.0L 4-cylinder supercharged engine, may have a condition where the malfunction indicator lamp illuminates, and/or there is a lack of engine power. This may be caused by failure of the catalytic converter. Do not take your vehicle to your GM dealer/retailer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the catalytic converter. If this condition occurs on your 2004-2007 model year Saturn ION Red Line or 2005-2007 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer/retailer. If you believe that your vehicle has the condition covered by this special coverage, you may want to contact your GM dealer/retailer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer/retailer to order parts if Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3907 they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by January 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer/retailer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension Technical Service Bulletin # 08020 Date: 100113 Campaign - Catalytic Converter Warranty Extension SPECIAL COVERAGE Bulletin No.: 08020 Date: January 13, 2010 Subject: 08020 - SPECIAL COVERAGE ADJUSTMENT - EXTENDED CATALYTIC CONVERTER WARRANTY COVERAGE Models: 2004-2007 SATURN ION RED LINE 2005-2007 CHEVROLET COBALT SS EQUIPPED WITH 2.0L 4-CYLINDER (RPO LSJ) ENGINE Condition Some customers of 2004-07 model year Saturn ION Red Line; and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, may comment on illumination of the malfunction indicator lamp (MAL) and/or lack of engine power. This may be caused by failure of the catalytic converter. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers/retailers are to replace the catalytic converter. The repairs will be made at no charge to the customer. Customers should not be charged for performing a system check when it is determined that the catalytic converter is not the cause of the customer complaint. Labor code T5725 is provided to submit claims for such system checks. Any additional necessary diagnosis and repairs that are not related to the catalytic converter are NOT covered by this special coverage. The customer should be informed that any further service that is not covered by the new vehicle warranty will not be covered by this policy. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 14, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 14, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-07 model year Saturn ION and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, and built within the following VIN breakpoints: Important Dealers/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverages are displayed in the Applicable Warranties section. Parts Information GM: Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO). Saturn US Only: Due to the limited number of affected vehicles, Saturn will not be doing a pre-shipment of parts. Retailers should order parts as needed from Saturn Service Parts Operations (SSPO). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3913 Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Service Procedure The purpose of this field action bulletin is to determine if it is necessary to replace the catalytic converter on certain 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine. The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to Strategy Based Diagnosis in SI. Determine the condition of the catalytic converter. Refer to Symptom - Engine Exhaust and Restricted Exhaust in SI. - If diagnosis indicates that the catalytic converter must be replaced, replace the Catalytic Converter. Refer to Catalytic Converter Replacement in SI. - If diagnosis indicates that the catalytic converter does NOT require replacement, determine the cause of the customer-reported exhaust concern using the diagnostic service information in SI. Diagnostic time and service repairs for exhaust system components other than the catalytic converter are NOT covered by this field action. Diagnostic time and service repair work for exhaust system components other than the catalytic converter must be billed under warranty or customer pay. Customer Reimbursement 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For GM US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3914 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to replace the catalytic converter are to be submitted to the dealer prior to or by January 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for this condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form is included with the customer letter. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers/retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter January 2010 Dear General Motors Customer: As the owner of a 2004-07 model year Saturn ION Red Line or 2005-07 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with a 2.0L 4-cylinder supercharged engine, may have a condition where the malfunction indicator lamp illuminates, and/or there is a lack of engine power. This may be caused by failure of the catalytic converter. Do not take your vehicle to your GM dealer/retailer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the catalytic converter. If this condition occurs on your 2004-2007 model year Saturn ION Red Line or 2005-2007 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer/retailer. If you believe that your vehicle has the condition covered by this special coverage, you may want to contact your GM dealer/retailer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer/retailer to order parts if Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 3915 they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by January 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer/retailer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 06-06-01-010A > Feb > 08 > Exhaust System - Catalytic Converter Precautions Catalytic Converter: All Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 06-06-01-010A > Feb > 08 > Exhaust System - Catalytic Converter Precautions Catalytic Converter: All Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3925 Catalytic Converter: Service and Repair Catalytic Converter Replacement (LSJ) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the post catalytic converter heated oxygen sensor (HO2S). 3. Remove the catalytic converter pipe-to-exhaust manifold nuts. 4. Carefully separate the converter pipe from the exhaust manifold. 5. Lower the converter pipe to rest on the rear crossmember of the front suspension frame. 6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts. 7. Position the converter pipe forward and support the pipe. 8. Move the extension pipe rearward and down in order to separate the pipes. 9. Remove the catalytic converter pipe assembly from the vehicle. 10. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets. 11. Clean the flange surfaces of any remaining gasket material. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3926 1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs. 2. Position the catalytic converter pipe assembly to the vehicle. 3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the catalytic converter pipe-to-exhaust extension pipe nuts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 5. Carefully install the converter pipe to the exhaust manifold. 6. Install the catalytic converter pipe-to-exhaust manifold nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 7. Install the post catalytic converter HO2S. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold to Cylinder Head Nut ............................................................................................................................................. 12 Nm (106 inch lbs.) Exhaust Manifold to Cylinder Head Stud .............................................................................................................................................. 10 Nm (89 inch lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair Intermediate Pipe Replacement Removal Procedure Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. Important: A service exhaust muffler will be needed when replacing the exhaust extension pipe on an originally equipped, welded system. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the exhaust muffler. 3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler. 4. Release the muffler from the underbody hanger insulators and remove the exhaust muffler. 5. Support the catalytic converter pipe. 6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts. 7. Release the exhaust extension pipe from the underbody hanger insulators, and support the extension pipe. 8. Separate the extension pipe from the converter pipe and remove the extension pipe from the vehicle. 9. Clean the converter pipe flange surface of any remaining gasket material. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 3933 1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.Connect the extension pipe to the converter pipe, and support the extension pipe. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the catalytic converter pipe-to-exhaust extension pipe nuts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 3. Install the exhaust extension pipe to the underbody hangers insulators. 4. Install the muffler to the vehicle. 5. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger. 6. Install a muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3⁄4 inch) from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister. 7. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia. 8. While maintaining muffler positioning, tighten the exhaust clamp nuts. ^ Tighten the nuts to 45 Nm (33 ft. lbs.). 9. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Wheel Drive Shaft Heat Shield Replacement Heat Shield: Service and Repair Wheel Drive Shaft Heat Shield Replacement Wheel Drive Shaft Heat Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel drive shaft heat shield-to-transmission mount bracket bolt. 3. Remove the drive shaft heat shield-to-engine block bolt. 4. Remove the wheel drive shaft heat shield. Installation Procedure 1. Install the wheel drive shaft heat shield into position on the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft heat shield-to-engine block bolt. ^ Tighten the bolt to 30 Nm (22 ft. lbs.). 3. Install the wheel drive shaft heat shield-to-transmission mount bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Wheel Drive Shaft Heat Shield Replacement > Page 3938 Heat Shield: Service and Repair Fuel Tank Heat Shield Replacement Fuel Tank Heat Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Release the exhaust extension pipe insulators (1, 2) from the underbody hangers. 3. Release the muffler insulator (3) from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam. 4. Support the LH side of the fuel tank, just clear of the fuel tank heat shield. 5. Remove the LH fuel tank strap bolts and the strap. 6. Using a flat-bladed screwdriver, release the heat shield push-rivet style retainers (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Wheel Drive Shaft Heat Shield Replacement > Page 3939 7. Remove the fuel tank heat shield from the vehicle. Installation Procedure 1. Carefully install the fuel tank heat shield into position on the fuel tank. 2. Install the heat shield retainers into position, then press to secure the retainers. Ensure that each of the retainers is fully seated. 3. Install the LH fuel tank strap and strap bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the fuel tank strap bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 5. Remove the support from the fuel tank. 6. Raise the exhaust into position and install the muffler insulator (3) to the underbody hanger. 7. Install the exhaust extension pipe insulators (1, 2) to the underbody hangers. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Wheel Drive Shaft Heat Shield Replacement > Page 3940 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Separate the post catalytic converter HO2S wiring (1) from the exhaust heat shield. 3. Remove the catalytic converter pipe from the vehicle, to access the center rivet on the exhaust heat shield. 4. Release the exhaust extension pipe forward insulators from the underbody hangers, and support the extension pipe. 5. Remove the exhaust heat shield retaining nut. 6. Drill out and remove the heat shield retaining rivets. 7. Remove the heat shield from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Wheel Drive Shaft Heat Shield Replacement > Page 3941 1. Install the exhaust heat shield into position on the vehicle. 2. Install new heat shield retaining rivets. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the exhaust heat shield retaining nut. ^ Tighten the nut to 10 Nm (89 inch lbs.). 4. Remove the support from the exhaust extension pipe. 5. Install the exhaust extension pipe forward insulators to the underbody hangers. 6. Install the catalytic converter pipe to the vehicle. 7. Install the post catalytic converter HO2S wiring (1). 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Replacement Removal Procedure Important: The originally equipped, welded exhaust extension pipe can be cut and reused when installing a service muffler, if the extension pipe is in acceptable condition. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the exhaust muffler. 3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler. 4. Release the muffler from the underbody hanger insulators and remove the exhaust muffler. 5. Deburr the extension pipe end, as necessary. Installation Procedure 1. Install the muffler to the vehicle. 2. Slide the muffler inlet pipe over the extension pipe, then install the muffler to the underbody hanger insulators. 3. Install a muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3⁄4 in) from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister. 4. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia. 5. Notice: Refer to Fastener Notice in Service Precautions. While maintaining muffler positioning, tighten the exhaust clamp nuts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 3945 ^ Tighten the nuts to 45 Nm (33 ft. lbs.). 6. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 3957 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 3967 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3973 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4051 Body Control Module (BCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4052 Body Control Module (BCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4053 Body Control Module (BCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4054 Body Control Module (BCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4055 Body Control Module (BCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4056 Body Control Module (BCM) C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4057 Body Control Module (BCM) C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Body Control Module (BCM) C3 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 Body Control Module (BCM) C4 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 Body Control Module (BCM) C4 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control module (BCM) has a bussed electrical center integrated into the housing. Body control relays and fuses are installed directly on the BCM, which simplifies wiring and junction blocks on the vehicle. The body control system consists of the BCM and its associated controls. Battery positive voltage is provided to the BCM from IBCM BATT 1 fuse and the IBCM BATT 2 fuse in the underhood fuse block. The module grounds are wired to ground G201, G203 and G305. The BCM is wired to the GMLAN High speed serial data buss, and the GMLAN Low speed serial data buss, as well as discrete input and output terminals to control the functions of the vehicle's body. Serial Data Gateway The body control module (BCM) in this vehicle functions as a translator between the High and Low speed GMLAN busses. The 2 communication protocols use the BCM to translate communicated serial data messages between the control modules over the 2 serial data busses. Power Mode Master This vehicles BCM functions as the Power Mode Master (PMM). Refer to Power Mode Description and Operation for a complete description of power mode functions. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The BCM functions include the following: A/C compressor request-Refer to Air Temperature Description and Operation in HVAC Systems Manual. - A/C cooling fan-Refer to Air Delivery Description and Operation in HVAC Systems - Manual. - Battery rundown protection (inadvertent power)-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Bulb check-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Chimes-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. Check gages - Door ajar warning - Headlamps ON - Key-in-ignition - Oil reset - Park brake warning - Seat belt not fastened - Turn signal ON - Door lock interface-Refer to Power Door Locks Description and Operation in Doors. - Electronic power steering (EPS)-Refer to Power Steering System Description and Operation in Power Steering System. - Engine coolant level sensing-Refer to Cooling System Description and Operation in Cooling System. - Exterior and interior lighting control-Refer to Exterior Lighting Systems Description and Operation in Lighting Systems. Automatic lighting control - Daytime running lamps (DRL) - Fog lamps - Park brake lights - Turn hazard lamps - Gage control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Horn interface-Refer to Horns System Description and Operation in Horns. - Instrument cluster indicator control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Interior lighting-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Key-in-ignition sensing-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. - Parking brake state sensing-Refer to Brake Warning System Description and Operation in Hydraulic Brakes. - Retained accessory power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Rear compartment interface-Refer to Power Door Locks Description and Operation in Doors. - Rear defogger-Refer to Rear Window Defogger Description and Operation in Heated Glass Element. - Remote function control-Refer to Keyless Entry System Description and Operation in Keyless Entry. - Seat belt use sensing-Refer to Seat Belt System Description and Operation in Seat Belts. - Content theft deterrent-Refer to Theft Systems Description and Operation in Theft Deterrent. - Vehicle theft deterrent-Refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Washer solvent level sensing-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. - Wiper/washer-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4063 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation for more information about the gateway. The powertrain control module (PCM) on this vehicle, uses a class 2 serial data buss. The class 2 buss is only used for diagnostics and the service programming system (SPS). During normal vehicle operations, there is no communications over the class 2 serial data buss. Normal vehicle operational messaging for the PCM is sent over the PCMs GMLAN high speed serial data buss. GMLAN HIGH SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. NOTE: a loss of serial data DTC does not represent a failure of the module that the code is set in. GMLAN LOW SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pules is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. CLASS 2 CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data circuit. Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7 volts nominal and inactive at ground potential. When the ignition switch is in RUN, and a scan tool is connected to the DLC, the powertrain control module (PCM) will start communicating diagnostic information over the class 2 serial data circuit. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Pin 1 GMLAN low speed communications terminal - Pin 2 Class 2 signal terminal - Pin 4 Scan tool power ground terminal - Pin 5 Common signal ground terminal - Pin 6 High speed GMLAN serial data bus (+) terminal - Pin 14 High speed GMLAN serial data bus (-) terminal - Pin 16 Scan tool power, battery positive voltage terminal CLASS 2 SERIAL DATA USAGE The class 2 serial data communications circuit on this vehicle is only used for powertrain control module (PCM) diagnostics and PCM service programming system (SPS) programming. SERIAL DATA REFERENCE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4064 The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4065 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION Power to many of this vehicle's circuits are controlled by the module that is designated the Power Mode Master (PMM). This vehicle's PMM is the Body Control Module (BCM). The PMM controls which power mode (Run, Accessory, Crank, Retained Accessory Power, or Off) is active. Serial Data Power Mode Master On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle, the PMM is the body control module (BCM). The PMM receives 3 discrete ignition switch signals to differentiate which power mode will be sent over the Serial Data circuits. The 3-wire Ignition Switch table illustrates the state of these inputs in correspondence to the ignition switch position. Relay Controlled Power Mode The body control module (BCM) uses the discrete ignition switch inputs Off/Run/Crank, Accessory, and ignition 1, to distinguish the correct power mode. The ignition 1 circuit is also routed to the Run/Crank relay for relay controlled power feeds during the appropriate power mode. The BCM, after determining the desired power mode, will activate the appropriate relays for that power mode. Run/Crank Relay The run/crank relay control circuit is connected to a constant ground and is switched by the ignition 1 circuit or the body control module (BCM). The BCM, will in lieu of the ignition switch position, activate the Run/Crank relay during a remote start event. The Run/Crank relay supplies a power signal to the following circuits, when the a Run or Crank power mode is selected: Automatic transmission shift indicator - Automatic transmission (A/T) - Switched power feeds to the BCM - Electronic brake control module (EBCM) - Electronic ignition module (spark control) - Electronic power steering module (EPS) - Fuel injectors - Powertrain control module (PCM) - Park neutral position (PNP) switch Accessory (ACC) Relay The adaptive cruise control (ACC) relay is energized when the Run or accessory power mode has been selected. The relay uses a Hot At All Times B+ power source derived from the underhood electrical center. The ACC relay is also energized by the body control module (BCM) to supply power during the retained accessory power (RAP) mode. The following devices are controlled by this relay: Inside rearview mirror - Heated seats - Power windows - Sunroof - Wiper washers switch Fail-Safe Operation Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the power mode master (PMM) fail to send a power mode message. The fail-safe plan covers those modules, using exclusively serial data control of power mode, as well as those modules with discrete ignition signal inputs. Serial Data Messages The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid power mode master (PMM) message until they can check for the engine run flag status on the serial data circuits. If the PMM fails, the modules monitor the serial data circuit for Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4066 the engine run flag serial data. If the engine run flag serial data is True, indicating that the engine is running, the modules fail-safe to RUN. In this state, the modules and their subsystems can support all operator requirements. If the engine run flag serial data is False, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Discrete Ignition Signals Those modules that have discrete ignition signal inputs, also remain in the state dictated by the last valid power mode master (PMM) message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, battery positive voltage, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 volts, the modules will fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. BCM Wake-Up/Sleep States The body control module (BCM) is able to control or perform all of the BCM functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system functions has stopped, and the BCM has become idle again. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors for these inputs during the sleep state, where the BCM is able to detect switch transitions that cause the BCM to wake-up when activated or deactivated. Multiple switch inputs are needed in order to sense both the insertion of the ignition key and the power mode requested. The BCM will enter a wake-up state, if any of the following wake-up inputs are detected: Activity on the serial data line - Detection of a battery disconnect and reconnect condition - Headlamps are ON. - Ignition is turned ON. - Key-in-ignition switch - Park lamps are ON. - RFA message The BCM will enter a sleep state when all of the following conditions exist: The ignition switch is OFF. - No activity exists on the serial data line. - No outputs are commanded. - No delay timers are actively counting. - No wake-up inputs are present. If all these conditions are met, the BCM will enter a low power or sleep condition. This condition indicates that the BCM, which is the power mode master (PMM) of the vehicle, has sent an OFF or OFF-ASLEEP message to the other systems on the serial data line. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 4067 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The Radio uses an exclusive RAP message that can not be circumvented by any door but the drives door. The BCM then sends a serial data power mode message ending the RAP function. The radio is the only module that is controlled by the serial data circuits. RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) The body control module (BCM) keeps the accessory relay energized during all power modes, except Off-Awake and Crank. The devices powered by the accessory relay during the retained accessory power (RAP) power mode are the sunroof and windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4070 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Scan Tool Does Not Communicate with Low Speed GMLAN Device See: Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With Low Speed GMLAN Device - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4071 Steps 1-12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4072 Steps 13-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4073 Steps 1-12 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle serial data communications and the control modules operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by a module which acts as the power mode master (PMM) in order to determine the correct power mode. The module which is the PMM communicates the system power mode to all modules on the serial data lines. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4074 Steps 1-6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4075 Steps 7-14 The numbers below refer to the step numbers on the diagnostic table. 6. This step tests for battery voltage on the incorrect signal circuits. 7. This step tests for no battery voltage on the required signal circuits. 8. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 9. This step eliminates open circuits as the cause of the malfunction. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4076 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Accessory Relay Command: The scan tool displays the state of the accessory relay command. Battery Voltage Signal: The scan tool displays the vehicle voltage. Ignition Mode Switch: The scan tool displays the ignition switch voltage signal. This signal is derived from the ignition Off/Run/Crank circuit. Ignition Switch Accessory: The scan tool displays the state of the ignition switch accessory circuit. Ignition Switch Run/Crank: The scan tool displays the state of the ignition switch Run/Crank circuit. Key In Ignition Cylinder: The scan tool displays whether or not the key is in the ignition cylinder. Power Mode: The scan tool displays the vehicle power mode. Run Relay Command: The scan tool displays the state of the Run relay. Run Crank Relay Command: The scan tool displays the state of the Run Crank relay. Vehicle Control Systems Data BCM Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. A new body control module (BCM) must be programmed with the proper regular production option (RPO) configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. The Tech 2 software will automatically prompt you with the RPO available for the vehicle. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the Vehicle Control Systems in Computer/Integrating Systems menu on the scan tool to program the BCM. Select Module Replacement/Setup and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passkey 3 Programming Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passkey 3 Programming procedure. Perform the Passkey 3 Programming Procedure if any of the following components have been replaced: The BCM - The powertrain control module (PCM)Refer to Programming Theft Deterrent System Components in Theft Deterrent for the proper procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4079 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 4083 Throttle Actuator Control (TAC) Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 4092 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4098 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 4103 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 05-05-25-001 > Jan > 05 > Engine Controls - False DTC U2108 Set Engine Control Module: All Technical Service Bulletins Engine Controls - False DTC U2108 Set Bulletin No.: 05-05-25-001 Date: January 04, 2005 INFORMATION Subject: Information on a Falsely Set DTC U2108 in Engine Control Module (ECM) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) with Non-ABS Brake System (RPO J41) Built Prior to February, 2005 Technicians may observe DTC U2108 (ECM Lost Communications With ABS/TCS Control System), current or in history, stored in the ECM when the vehicle is connected to the Tech 2(R). This DTC is associated with ABS equipped vehicles. Because the above vehicle is not equipped with ABS, this may cause confusion. The ECM may falsely set a DTC U2108 in cars not equipped with ABS due to a software condition. A DTC U2108 will NOT illuminate a SES/MIL light. A code clear will only momentarily clear this DTC and will return to a current state almost immediately. No repairs to the vehicle are necessary as a result of a DTC U2108. DO NOT REPLACE THE BCM OR ECM. If the SES/MIL light is illuminated with a DTC U2108 present, look for additional DTCs causing the condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 4117 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 05-05-25-001 > Jan > 05 > Engine Controls - False DTC U2108 Set Engine Control Module: All Technical Service Bulletins Engine Controls - False DTC U2108 Set Bulletin No.: 05-05-25-001 Date: January 04, 2005 INFORMATION Subject: Information on a Falsely Set DTC U2108 in Engine Control Module (ECM) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) with Non-ABS Brake System (RPO J41) Built Prior to February, 2005 Technicians may observe DTC U2108 (ECM Lost Communications With ABS/TCS Control System), current or in history, stored in the ECM when the vehicle is connected to the Tech 2(R). This DTC is associated with ABS equipped vehicles. Because the above vehicle is not equipped with ABS, this may cause confusion. The ECM may falsely set a DTC U2108 in cars not equipped with ABS due to a software condition. A DTC U2108 will NOT illuminate a SES/MIL light. A code clear will only momentarily clear this DTC and will return to a current state almost immediately. No repairs to the vehicle are necessary as a result of a DTC U2108. DO NOT REPLACE THE BCM OR ECM. If the SES/MIL light is illuminated with a DTC U2108 present, look for additional DTCs causing the condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4126 Engine and Transmission Modules Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 Powertrain Control Module (PCM) C3 (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 4212 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCs) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 4213 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The engine knock sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 4214 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) is the control center for the throttle actuator control (TAC) system. The PCM determines the drivers intent and then calculates the appropriate throttle response. The PCM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4215 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. Disconnect the 3 powertrain control module (PCM) harness connectors from the PCM, noting proper orientation. 4. Use the retaining tab to release the PCM from the underhood junction block bracket. INSTALLATION PROCEDURE 1. Use the retaining tab to secure the PCM, when installing the PCM to the underhood junction block bracket. 2. Connect the PCM harness connectors to the PCM. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Ignition Coil/module 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4299 Ignition Coil/Module 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4300 Ignition Coil/module 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4301 Ignition Coil/Module 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 4302 Ignition Control Module: Description and Operation IGNITION COIL/MODULE Each ignition coil/module has the following circuits: - An ignition voltage circuit - A ground - An ignition control (IC) circuit - A low reference circuit The PCM controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event. The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4308 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4309 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4390 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Top Left Side of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4394 Barometric Pressure Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4395 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor harness connector. 2. Remove the BARO sensor bracket and bolt. 3. Remove the BARO sensor (2). INSTALLATION PROCEDURE 1. Install the BARO sensor (2). 2. Install the BARO sensor bracket and bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the BARO sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4399 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4400 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4481 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4482 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4483 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 4487 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 4488 Clutch Pedal Position (CPP) Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4492 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4493 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4494 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4495 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4576 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4579 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The powertrain control module (PCM) sends the fuel level information via the GMLAN serial data circuit to the body control module (BCM). The BCM sends the GMLAN message to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4583 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the fuel pump module assembly. 2. Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl. 3. Disconnect the fuel level sensor electrical connector from the pump module. 4. Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module. 5. Carefully slide the level sensor the rest of the way off of the pump module. INSTALLATION PROCEDURE 1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. 2. Secure the retaining tab (2) on the sensor into the slot on the pump module bowl. 3. Connect the fuel level sensor electrical connector to the pump module. 4. Install the fuel level sensor wiring harness to the molded-in tab (1) on the pump module bowl. 5. Install the fuel pump module assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4587 Fuel Tank Pressure (FTP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4588 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4589 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4. Carefully use the screwdrivers to lift and release the sensor from the fuel pump module. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4590 1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor grommet is fully seated to the pump module. 2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4594 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4595 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor harness connector. 2. Remove the IAT sensor bolt. 3. While twisting the IAT sensor (3), pull the sensor from the engine. INSTALLATION PROCEDURE 1. Press the IAT sensor (3) into the engine. 2. Install the IAT sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the IAT sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4675 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4676 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4680 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (TMAP) REMOVAL PROCEDURE 1. Disconnect the temperature manifold absolute pressure (TMAP) sensor harness connector. 2. Remove the TMAP sensor from the intake manifold. 3. Inspect the seal for damage. IMPORTANT: If the TMAP sensor seal is damaged, the TMAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the TMAP sensor into the intake manifold. IMPORTANT: Use the new TMAP sensor seal provided with the new TMAP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the TMAP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) > Page 4683 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (SCIP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (SCIP) REMOVAL PROCEDURE 1. Disconnect the supercharger inlet pressure (SCIP) sensor harness connector. 2. Remove the SCIP sensor (1) from the supercharger. 3. Inspect the seal for damage. IMPORTANT: If the SCIP sensor seal is damaged, the SCIP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the SCIP sensor (1) into the intake manifold. IMPORTANT: Use the new SCIP sensor seal provided with the new SCIP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the SCIP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Rear of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4690 HO2S 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) - 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Heated Oxygen Sensor (HO2S) - 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 1 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor using J 39194-C. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 4771 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 4772 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 2 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 2 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel drive shaft heat shield. 3. Note the routing of the heated oxygen sensor (HO2S) electrical harness. 4. Disconnect the HO2S electrical connector (2), in the engine compartment. 5. Carefully bend the edge of the channel on the LH side of the exhaust heat shield outboard, just enough to release the HO2S electrical harness (1). 6. Using the J 39194 carefully remove the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. - Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 4773 7. Lower the HO2S electrical harness away from the underbody. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 24185279, or equivalent. 2. Carefully install the HO2S to the pipe. 3. Using the J 39194, or equivalent, tighten the HO2S. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten the HO2S to 41 N.m (30 lb ft). 4. Install the HO2S electrical harness into position as noted before removal. 5. Carefully bend the edge of the channel (1) on the LH side of the exhaust heat shield inboard, just enough to secure the HO2S electrical harness in the channel. IMPORTANT: Use care when securing the HO2S electrical harness into the channel on the exhaust heat shield, to not pinch the wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 4774 6. Connect the HO2S electrical connector (2). 7. Install the wheel drive shaft heat shield. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4856 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4857 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4858 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4859 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 4860 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed > Page 4865 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed Vehicle Speed Sensor: Service and Repair Getrag 5 Speed Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Pull up on the VSS in order to remove the VSS from the transaxle. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 4868 3. Install the VSS assembly. 4. Install the VSS retainer. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 12 Nm (8 ft. lbs.). 6. Connect the VSS connector to the VSS. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 4869 Vehicle Speed Sensor: Service and Repair MU3 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the left front wheel. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the retainer bolt. 4. Remove the retainer. 5. Remove the VSS. 6. Remove and discard the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid Saturn P/N 121019223. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 4870 3. Install the VSS retainer.Install the vehicle speed sensor (VSS) assembly. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS (2). 6. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 4871 Vehicle Speed Sensor: Service and Repair 4T40-E/4T45-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable from the battery negative terminal. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to the case. Installation Procedure 1. Clean and dry the vehicle speed sensor. 2. Notice: Install the vehicle speed sensor and the retaining bolt. ^ Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Remove the safety stands. 5. Lower the vehicle. 6. Connect the negative battery cable. ^ Tighten the terminal bolt to 15 Nm (11 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4876 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4877 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4958 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5118 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5119 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5120 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5201 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5204 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5218 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5219 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5220 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 5229 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5239 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5240 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 5241 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 5250 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5339 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5340 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5347 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5348 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cracking times. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5349 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5350 Steps 7 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: Customer Interest Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 5359 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: All Technical Service Bulletins Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 5365 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5366 Idle Speed: By Symptom Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5367 Disclaimer Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5368 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 5369 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Intake Duct Replacement AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front tire and wheel. 2. Remove the left front fender liner. 3. Remove the air cleaner intake duct assembly push-in fasteners. 4. Remove the air cleaner intake duct assembly bolt. 5. Remove the intake duct assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the intake duct assembly. 2. Install the intake duct assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb ft). 3. Install the intake duct assembly push in fasteners. 4. Install the left front fender liner. 5. Install the left front tire and wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 5375 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly air duct at the outlet duct clamp 1. 2. Loosen the outlet duct clamp 2 at the throttle body. 3. Remove the air outlet duct. INSTALLATION PROCEDURE 1. Install the air outlet duct. 2. Install the air outlet duct clamps 1 and 2. 3. Tighten the air outlet duct clamps 1 and 2. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 5376 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5385 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5391 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5392 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Loosen the air cleaner cover screws (1). 3. Remove the air cleaner cover (2). 4. Remove the air cleaner filter from the air cleaner housing (3). INSTALLATION PROCEDURE 1. Install the air cleaner filter into the air cleaner housing. 2. Install the air cleaner cover to the air cleaner housing. 3. Install the air cleaner housing cover screws (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5393 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air cleaner housing screws to 3 N.m (27 lb in). 4. Install the air cleaner assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 5399 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 5400 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... .................................... 25 - 30 Nm (18.4 - 22.1 lb ft) Spark Plug Gap ................................................ ............................................................................................................................................... 1 mm (0.04 in) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5407 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................... GM P/N 12787099 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5408 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5409 - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5410 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coils. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT coat the spark plugs with anti-seize compound. Over torquing could occur and damage to the cylinder head threads may Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 5411 result. Tighten the spark plugs to 20 N.m (15 lb ft). 3. Install the ignition coils. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70 percent of the highest. No cylinder reading should be less than 689 kPa (100 psi) Compression Ratio ................................................................. ...................................................................................................................................... 9.5:01 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 5415 Compression Check: Testing and Inspection Engine Compression Test Perform the following steps to conduct a compression test. 1. Conduct the following steps to check cylinder compression. 1. Engine should be at room temperature. 2. Disconnect wiring from the ignition module. 3. Remove the spark plugs. 4. Throttle body valve should be wide open. 5. Battery should be at or near full charge. 2. For each cylinder, crank engine through 4 compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal. Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings. Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves. Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately 3 squirts from a plunger-type oiler. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5420 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5421 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 5502 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5506 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 5507 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor harness connector. 2. Remove the IAT sensor bolt. 3. While twisting the IAT sensor (3), pull the sensor from the engine. INSTALLATION PROCEDURE 1. Press the IAT sensor (3) into the engine. 2. Install the IAT sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the IAT sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Top Left Side of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5511 Barometric Pressure Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5512 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor harness connector. 2. Remove the BARO sensor bracket and bolt. 3. Remove the BARO sensor (2). INSTALLATION PROCEDURE 1. Install the BARO sensor (2). 2. Install the BARO sensor bracket and bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the BARO sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 5516 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 5517 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments Backlighting Inoperative During Daylight Body Control Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments Backlighting Inoperative During Daylight > Page 5526 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 5536 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5542 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Body Control Module (BCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Body Control Module (BCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Body Control Module (BCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Body Control Module (BCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Body Control Module (BCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Body Control Module (BCM) C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Body Control Module (BCM) C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Body Control Module (BCM) C3 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Body Control Module (BCM) C4 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Body Control Module (BCM) C4 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control module (BCM) has a bussed electrical center integrated into the housing. Body control relays and fuses are installed directly on the BCM, which simplifies wiring and junction blocks on the vehicle. The body control system consists of the BCM and its associated controls. Battery positive voltage is provided to the BCM from IBCM BATT 1 fuse and the IBCM BATT 2 fuse in the underhood fuse block. The module grounds are wired to ground G201, G203 and G305. The BCM is wired to the GMLAN High speed serial data buss, and the GMLAN Low speed serial data buss, as well as discrete input and output terminals to control the functions of the vehicle's body. Serial Data Gateway The body control module (BCM) in this vehicle functions as a translator between the High and Low speed GMLAN busses. The 2 communication protocols use the BCM to translate communicated serial data messages between the control modules over the 2 serial data busses. Power Mode Master This vehicles BCM functions as the Power Mode Master (PMM). Refer to Power Mode Description and Operation for a complete description of power mode functions. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The BCM functions include the following: A/C compressor request-Refer to Air Temperature Description and Operation in HVAC Systems Manual. - A/C cooling fan-Refer to Air Delivery Description and Operation in HVAC Systems - Manual. - Battery rundown protection (inadvertent power)-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Bulb check-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Chimes-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. Check gages - Door ajar warning - Headlamps ON - Key-in-ignition - Oil reset - Park brake warning - Seat belt not fastened - Turn signal ON - Door lock interface-Refer to Power Door Locks Description and Operation in Doors. - Electronic power steering (EPS)-Refer to Power Steering System Description and Operation in Power Steering System. - Engine coolant level sensing-Refer to Cooling System Description and Operation in Cooling System. - Exterior and interior lighting control-Refer to Exterior Lighting Systems Description and Operation in Lighting Systems. Automatic lighting control - Daytime running lamps (DRL) - Fog lamps - Park brake lights - Turn hazard lamps - Gage control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Horn interface-Refer to Horns System Description and Operation in Horns. - Instrument cluster indicator control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Interior lighting-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Key-in-ignition sensing-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. - Parking brake state sensing-Refer to Brake Warning System Description and Operation in Hydraulic Brakes. - Retained accessory power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Rear compartment interface-Refer to Power Door Locks Description and Operation in Doors. - Rear defogger-Refer to Rear Window Defogger Description and Operation in Heated Glass Element. - Remote function control-Refer to Keyless Entry System Description and Operation in Keyless Entry. - Seat belt use sensing-Refer to Seat Belt System Description and Operation in Seat Belts. - Content theft deterrent-Refer to Theft Systems Description and Operation in Theft Deterrent. - Vehicle theft deterrent-Refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Washer solvent level sensing-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. - Wiper/washer-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5632 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation for more information about the gateway. The powertrain control module (PCM) on this vehicle, uses a class 2 serial data buss. The class 2 buss is only used for diagnostics and the service programming system (SPS). During normal vehicle operations, there is no communications over the class 2 serial data buss. Normal vehicle operational messaging for the PCM is sent over the PCMs GMLAN high speed serial data buss. GMLAN HIGH SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. NOTE: a loss of serial data DTC does not represent a failure of the module that the code is set in. GMLAN LOW SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pules is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. CLASS 2 CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data circuit. Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7 volts nominal and inactive at ground potential. When the ignition switch is in RUN, and a scan tool is connected to the DLC, the powertrain control module (PCM) will start communicating diagnostic information over the class 2 serial data circuit. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Pin 1 GMLAN low speed communications terminal - Pin 2 Class 2 signal terminal - Pin 4 Scan tool power ground terminal - Pin 5 Common signal ground terminal - Pin 6 High speed GMLAN serial data bus (+) terminal - Pin 14 High speed GMLAN serial data bus (-) terminal - Pin 16 Scan tool power, battery positive voltage terminal CLASS 2 SERIAL DATA USAGE The class 2 serial data communications circuit on this vehicle is only used for powertrain control module (PCM) diagnostics and PCM service programming system (SPS) programming. SERIAL DATA REFERENCE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5633 The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5634 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION Power to many of this vehicle's circuits are controlled by the module that is designated the Power Mode Master (PMM). This vehicle's PMM is the Body Control Module (BCM). The PMM controls which power mode (Run, Accessory, Crank, Retained Accessory Power, or Off) is active. Serial Data Power Mode Master On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle, the PMM is the body control module (BCM). The PMM receives 3 discrete ignition switch signals to differentiate which power mode will be sent over the Serial Data circuits. The 3-wire Ignition Switch table illustrates the state of these inputs in correspondence to the ignition switch position. Relay Controlled Power Mode The body control module (BCM) uses the discrete ignition switch inputs Off/Run/Crank, Accessory, and ignition 1, to distinguish the correct power mode. The ignition 1 circuit is also routed to the Run/Crank relay for relay controlled power feeds during the appropriate power mode. The BCM, after determining the desired power mode, will activate the appropriate relays for that power mode. Run/Crank Relay The run/crank relay control circuit is connected to a constant ground and is switched by the ignition 1 circuit or the body control module (BCM). The BCM, will in lieu of the ignition switch position, activate the Run/Crank relay during a remote start event. The Run/Crank relay supplies a power signal to the following circuits, when the a Run or Crank power mode is selected: Automatic transmission shift indicator - Automatic transmission (A/T) - Switched power feeds to the BCM - Electronic brake control module (EBCM) - Electronic ignition module (spark control) - Electronic power steering module (EPS) - Fuel injectors - Powertrain control module (PCM) - Park neutral position (PNP) switch Accessory (ACC) Relay The adaptive cruise control (ACC) relay is energized when the Run or accessory power mode has been selected. The relay uses a Hot At All Times B+ power source derived from the underhood electrical center. The ACC relay is also energized by the body control module (BCM) to supply power during the retained accessory power (RAP) mode. The following devices are controlled by this relay: Inside rearview mirror - Heated seats - Power windows - Sunroof - Wiper washers switch Fail-Safe Operation Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the power mode master (PMM) fail to send a power mode message. The fail-safe plan covers those modules, using exclusively serial data control of power mode, as well as those modules with discrete ignition signal inputs. Serial Data Messages The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid power mode master (PMM) message until they can check for the engine run flag status on the serial data circuits. If the PMM fails, the modules monitor the serial data circuit for Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5635 the engine run flag serial data. If the engine run flag serial data is True, indicating that the engine is running, the modules fail-safe to RUN. In this state, the modules and their subsystems can support all operator requirements. If the engine run flag serial data is False, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Discrete Ignition Signals Those modules that have discrete ignition signal inputs, also remain in the state dictated by the last valid power mode master (PMM) message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, battery positive voltage, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 volts, the modules will fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. BCM Wake-Up/Sleep States The body control module (BCM) is able to control or perform all of the BCM functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system functions has stopped, and the BCM has become idle again. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors for these inputs during the sleep state, where the BCM is able to detect switch transitions that cause the BCM to wake-up when activated or deactivated. Multiple switch inputs are needed in order to sense both the insertion of the ignition key and the power mode requested. The BCM will enter a wake-up state, if any of the following wake-up inputs are detected: Activity on the serial data line - Detection of a battery disconnect and reconnect condition - Headlamps are ON. - Ignition is turned ON. - Key-in-ignition switch - Park lamps are ON. - RFA message The BCM will enter a sleep state when all of the following conditions exist: The ignition switch is OFF. - No activity exists on the serial data line. - No outputs are commanded. - No delay timers are actively counting. - No wake-up inputs are present. If all these conditions are met, the BCM will enter a low power or sleep condition. This condition indicates that the BCM, which is the power mode master (PMM) of the vehicle, has sent an OFF or OFF-ASLEEP message to the other systems on the serial data line. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 5636 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The Radio uses an exclusive RAP message that can not be circumvented by any door but the drives door. The BCM then sends a serial data power mode message ending the RAP function. The radio is the only module that is controlled by the serial data circuits. RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) The body control module (BCM) keeps the accessory relay energized during all power modes, except Off-Awake and Crank. The devices powered by the accessory relay during the retained accessory power (RAP) power mode are the sunroof and windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5639 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Scan Tool Does Not Communicate with Low Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With Low Speed GMLAN Device - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5640 Steps 1-12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5641 Steps 13-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5642 Steps 1-12 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle serial data communications and the control modules operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by a module which acts as the power mode master (PMM) in order to determine the correct power mode. The module which is the PMM communicates the system power mode to all modules on the serial data lines. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5643 Steps 1-6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5644 Steps 7-14 The numbers below refer to the step numbers on the diagnostic table. 6. This step tests for battery voltage on the incorrect signal circuits. 7. This step tests for no battery voltage on the required signal circuits. 8. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 9. This step eliminates open circuits as the cause of the malfunction. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5645 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Accessory Relay Command: The scan tool displays the state of the accessory relay command. Battery Voltage Signal: The scan tool displays the vehicle voltage. Ignition Mode Switch: The scan tool displays the ignition switch voltage signal. This signal is derived from the ignition Off/Run/Crank circuit. Ignition Switch Accessory: The scan tool displays the state of the ignition switch accessory circuit. Ignition Switch Run/Crank: The scan tool displays the state of the ignition switch Run/Crank circuit. Key In Ignition Cylinder: The scan tool displays whether or not the key is in the ignition cylinder. Power Mode: The scan tool displays the vehicle power mode. Run Relay Command: The scan tool displays the state of the Run relay. Run Crank Relay Command: The scan tool displays the state of the Run Crank relay. Vehicle Control Systems Data BCM Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. A new body control module (BCM) must be programmed with the proper regular production option (RPO) configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. The Tech 2 software will automatically prompt you with the RPO available for the vehicle. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the Vehicle Control Systems in Computer/Integrating Systems menu on the scan tool to program the BCM. Select Module Replacement/Setup and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passkey 3 Programming Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passkey 3 Programming procedure. Perform the Passkey 3 Programming Procedure if any of the following components have been replaced: The BCM - The powertrain control module (PCM)Refer to Programming Theft Deterrent System Components in Theft Deterrent for the proper procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 5648 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5729 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5730 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 5731 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 5735 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 5736 Clutch Pedal Position (CPP) Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5740 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5741 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5742 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 5743 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5824 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5827 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5831 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 5832 I/P Harness Routing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation Electronic Throttle Actuator: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) SYSTEM DESCRIPTION PURPOSE The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: Accelerator pedal position (APP) sensing - Throttle positioning to meet driver and engine demands - Throttle position (TP) sensing - Internal diagnostics - Cruise control functions - Manage TAC electrical power consumption The TAC system includes the following components: The APP sensors - The throttle body assembly - The powertrain control module (PCM) ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. THROTTLE BODY ASSEMBLY The throttle assembly contains the following components: The throttle blade - The throttle actuator motor - The throttle position (TP) sensor 1 and 2 The throttle body functions similar to a conventional throttle body with the following exceptions: An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors are used to determine the throttle plate angle. The TP sensors provide the powertrain control module (PCM) with a signal voltage proportional to throttle plate movement. The TP sensor 1 signal voltage at closed throttle is near the 5-volt reference and decreases as the throttle plate is opened. The TP sensor 2 signal voltage at closed throttle is near the low reference and increases as the throttle plate is opened. POWERTRAIN CONTROL MODULE The powertrain control module (PCM) is the control center for the throttle actuator control (TAC) system. The PCM determines the drivers intent and then calculates the appropriate throttle response. The PCM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. MODES OF OPERATION Normal Mode During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation: Minimum pedal value-At key-up the powertrain control module (PCM) updates the learned minimum pedal value. - Minimum throttle position (TP) values-At key-up the PCM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. - Ice break mode-If the throttle is not able to reach a predetermined minimum TP, the ice break mode is entered. During the ice break mode, the PCM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. - Battery saver mode-After a predetermined time without engine RPM, the PCM commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation > Page 5836 Reduced Engine Power Mode When the PCM detects a condition with the TAC system, the PCM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: Acceleration limiting-The PCM will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. - Limited throttle mode-The PCM will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. - Throttle default mode-The PCM will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. - Forced idle mode-The PCM will perform the following actions: Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. - Ignore the accelerator pedal input. - Engine shutdown mode-The PCM will disable fuel and de-energize the throttle actuator. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 5840 Throttle Actuator Control (TAC) Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The powertrain control module (PCM) sends the fuel level information via the GMLAN serial data circuit to the body control module (BCM). The BCM sends the GMLAN message to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 5844 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the fuel pump module assembly. 2. Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl. 3. Disconnect the fuel level sensor electrical connector from the pump module. 4. Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module. 5. Carefully slide the level sensor the rest of the way off of the pump module. INSTALLATION PROCEDURE 1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. 2. Secure the retaining tab (2) on the sensor into the slot on the pump module bowl. 3. Connect the fuel level sensor electrical connector to the pump module. 4. Install the fuel level sensor wiring harness to the molded-in tab (1) on the pump module bowl. 5. Install the fuel pump module assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5848 Fuel Tank Pressure (FTP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5849 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5850 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4. Carefully use the screwdrivers to lift and release the sensor from the fuel pump module. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 5851 1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor grommet is fully seated to the pump module. 2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Data Link Connector (DLC) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Information Bus: Symptom Related Diagnostic Procedures Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION The powertrain control module (PCM) is connected to the class 2 serial data circuit. The class 2 serial data circuit is used for diagnostic purposes only in this vehicle. Connecting a scan tool to the data link connector (DLC) allows communication with the PCM for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS The PCM is the only module on the class 2 serial data buss on this vehicle. The most likely cause of the buss failure will be a short or open. TEST DESCRIPTION Steps 1-8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5933 Steps 9-13 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss or intermittent loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 10. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 11. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Communicate With High Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications on the high speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module detects a bus-off condition a DTC U0001 or U2100 will be set. These DTCs can be retrieved as history only. Diagnostic Aids The high speed GMLAN serial data buss uses two 120 ohms terminating resistors that are in parallel with the high speed GMLAN (+) and (-) circuits. One of the resistors is connected at the data link connector (DLC) end of the link and the other is at the engine management module, engine control module (ECM) or powertrain control module (PCM), end of the link. The DLC terminating resistor resides internally in the body control module (BCM). When testing for a short between high speed GMLAN (+) and (-) with the engine management module removed, a reading off 120 ohms is normal. However, to completely analyze the buss the BCM should be temporally removed when testing for shorts between the high speed GMLAN (+) and (-) while also making sure that all modules and the scan tool are disconnected from the buss. A normal reading across the high speed GMLAN buss with the terminating resistor at the DLC remove and all module and scan tool disconnected is infinite ohms. Make certain to reconnect the BCM after testing, it is necessary for proper vehicle powermoding. The engine will not start when there is a total malfunction of the high speed GMLAN serial data circuits while the engine is not running. The following conditions may cause a total loss of high speed GMLAN data communication: A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5934 Steps 1-9 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5935 Steps 10-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5936 Steps 18-19 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the high speed GMLAN serial data circuits uses a different procedure from a total malfunction of the high speed GMLAN data circuits. Refer to Data Link References to identify which modules communicate on the high speed GMLAN serial data circuits. 3. The DTC U2100 may be retrieved with a history status, but is not the cause of the present condition. 8. Data link connector terminals 6 and 14 provide the connection to the GMLAN serial data high circuit and the GMLAN serial data low circuit respectively. 17. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Communicate With Low Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH LOW SPEED GMLAN DEVICE Modules connected to the low speed GMLAN serial data circuits monitor for serial data communications on the low speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module detects a bus-off condition, DTC U2100 will be set. These DTCs can be retrieved as history only. Diagnostic Aids The engine will not start when there is a total malfunction of the low speed GMLAN serial data circuits while the engine is not running. The following conditions may cause a total loss of low speed GMLAN data communication: Any of the low speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the low speed GMLAN circuits Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5937 Steps 1-8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5938 Steps 9-18 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the low speed GMLAN serial data circuits uses a different procedure from a total malfunction of the low speed GMLAN data circuits. Refer to Data Link References to identify which modules communicate on the low speed GMLAN serial data circuits. 3. The DTC U2100 may be retrieved with a history status, but is not the cause of the present condition. 7. Data link connector terminal 1 provides the connection to the GMLAN serial data low circuit and the GMLAN serial data low circuit respectively. 16. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5939 SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry-wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 The scan tool will power up with the ignition OFF. Some modules, however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5940 Information Bus: Scan Tool Testing and Procedures DATA LINK REFERENCES This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits, refer to Data Link Communications Description and Operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6020 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6021 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied directly to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1 - 6 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6027 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 6028 Steps 1 - 11 The number below refers to the step number on the diagnostic table. 3. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 6032 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (TMAP) REMOVAL PROCEDURE 1. Disconnect the temperature manifold absolute pressure (TMAP) sensor harness connector. 2. Remove the TMAP sensor from the intake manifold. 3. Inspect the seal for damage. IMPORTANT: If the TMAP sensor seal is damaged, the TMAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the TMAP sensor into the intake manifold. IMPORTANT: Use the new TMAP sensor seal provided with the new TMAP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the TMAP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) > Page 6035 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (SCIP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (SCIP) REMOVAL PROCEDURE 1. Disconnect the supercharger inlet pressure (SCIP) sensor harness connector. 2. Remove the SCIP sensor (1) from the supercharger. 3. Inspect the seal for damage. IMPORTANT: If the SCIP sensor seal is damaged, the SCIP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the SCIP sensor (1) into the intake manifold. IMPORTANT: Use the new SCIP sensor seal provided with the new SCIP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the SCIP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Rear of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 6042 HO2S 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) - 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Heated Oxygen Sensor (HO2S) - 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 1 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: - The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor using J 39194-C. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6123 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6124 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 2 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 2 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel drive shaft heat shield. 3. Note the routing of the heated oxygen sensor (HO2S) electrical harness. 4. Disconnect the HO2S electrical connector (2), in the engine compartment. 5. Carefully bend the edge of the channel on the LH side of the exhaust heat shield outboard, just enough to release the HO2S electrical harness (1). 6. Using the J 39194 carefully remove the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. - Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6125 7. Lower the HO2S electrical harness away from the underbody. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 24185279, or equivalent. 2. Carefully install the HO2S to the pipe. 3. Using the J 39194, or equivalent, tighten the HO2S. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten the HO2S to 41 N.m (30 lb ft). 4. Install the HO2S electrical harness into position as noted before removal. 5. Carefully bend the edge of the channel (1) on the LH side of the exhaust heat shield inboard, just enough to secure the HO2S electrical harness in the channel. IMPORTANT: Use care when securing the HO2S electrical harness into the channel on the exhaust heat shield, to not pinch the wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6126 6. Connect the HO2S electrical connector (2). 7. Install the wheel drive shaft heat shield. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 6136 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 6146 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 6152 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Body Control Module (BCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Body Control Module (BCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Body Control Module (BCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Body Control Module (BCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 Body Control Module (BCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Body Control Module (BCM) C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 Body Control Module (BCM) C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Body Control Module (BCM) C3 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Body Control Module (BCM) C4 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Body Control Module (BCM) C4 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control module (BCM) has a bussed electrical center integrated into the housing. Body control relays and fuses are installed directly on the BCM, which simplifies wiring and junction blocks on the vehicle. The body control system consists of the BCM and its associated controls. Battery positive voltage is provided to the BCM from IBCM BATT 1 fuse and the IBCM BATT 2 fuse in the underhood fuse block. The module grounds are wired to ground G201, G203 and G305. The BCM is wired to the GMLAN High speed serial data buss, and the GMLAN Low speed serial data buss, as well as discrete input and output terminals to control the functions of the vehicle's body. Serial Data Gateway The body control module (BCM) in this vehicle functions as a translator between the High and Low speed GMLAN busses. The 2 communication protocols use the BCM to translate communicated serial data messages between the control modules over the 2 serial data busses. Power Mode Master This vehicles BCM functions as the Power Mode Master (PMM). Refer to Power Mode Description and Operation for a complete description of power mode functions. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The BCM functions include the following: A/C compressor request-Refer to Air Temperature Description and Operation in HVAC Systems Manual. - A/C cooling fan-Refer to Air Delivery Description and Operation in HVAC Systems - Manual. - Battery rundown protection (inadvertent power)-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Bulb check-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Chimes-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. Check gages - Door ajar warning - Headlamps ON - Key-in-ignition - Oil reset - Park brake warning - Seat belt not fastened - Turn signal ON - Door lock interface-Refer to Power Door Locks Description and Operation in Doors. - Electronic power steering (EPS)-Refer to Power Steering System Description and Operation in Power Steering System. - Engine coolant level sensing-Refer to Cooling System Description and Operation in Cooling System. - Exterior and interior lighting control-Refer to Exterior Lighting Systems Description and Operation in Lighting Systems. Automatic lighting control - Daytime running lamps (DRL) - Fog lamps - Park brake lights - Turn hazard lamps - Gage control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Horn interface-Refer to Horns System Description and Operation in Horns. - Instrument cluster indicator control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Interior lighting-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Key-in-ignition sensing-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. - Parking brake state sensing-Refer to Brake Warning System Description and Operation in Hydraulic Brakes. - Retained accessory power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Rear compartment interface-Refer to Power Door Locks Description and Operation in Doors. - Rear defogger-Refer to Rear Window Defogger Description and Operation in Heated Glass Element. - Remote function control-Refer to Keyless Entry System Description and Operation in Keyless Entry. - Seat belt use sensing-Refer to Seat Belt System Description and Operation in Seat Belts. - Content theft deterrent-Refer to Theft Systems Description and Operation in Theft Deterrent. - Vehicle theft deterrent-Refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Washer solvent level sensing-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. - Wiper/washer-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6242 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation for more information about the gateway. The powertrain control module (PCM) on this vehicle, uses a class 2 serial data buss. The class 2 buss is only used for diagnostics and the service programming system (SPS). During normal vehicle operations, there is no communications over the class 2 serial data buss. Normal vehicle operational messaging for the PCM is sent over the PCMs GMLAN high speed serial data buss. GMLAN HIGH SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. NOTE: a loss of serial data DTC does not represent a failure of the module that the code is set in. GMLAN LOW SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pules is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. CLASS 2 CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data circuit. Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7 volts nominal and inactive at ground potential. When the ignition switch is in RUN, and a scan tool is connected to the DLC, the powertrain control module (PCM) will start communicating diagnostic information over the class 2 serial data circuit. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Pin 1 GMLAN low speed communications terminal - Pin 2 Class 2 signal terminal - Pin 4 Scan tool power ground terminal - Pin 5 Common signal ground terminal - Pin 6 High speed GMLAN serial data bus (+) terminal - Pin 14 High speed GMLAN serial data bus (-) terminal - Pin 16 Scan tool power, battery positive voltage terminal CLASS 2 SERIAL DATA USAGE The class 2 serial data communications circuit on this vehicle is only used for powertrain control module (PCM) diagnostics and PCM service programming system (SPS) programming. SERIAL DATA REFERENCE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6243 The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6244 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION Power to many of this vehicle's circuits are controlled by the module that is designated the Power Mode Master (PMM). This vehicle's PMM is the Body Control Module (BCM). The PMM controls which power mode (Run, Accessory, Crank, Retained Accessory Power, or Off) is active. Serial Data Power Mode Master On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle, the PMM is the body control module (BCM). The PMM receives 3 discrete ignition switch signals to differentiate which power mode will be sent over the Serial Data circuits. The 3-wire Ignition Switch table illustrates the state of these inputs in correspondence to the ignition switch position. Relay Controlled Power Mode The body control module (BCM) uses the discrete ignition switch inputs Off/Run/Crank, Accessory, and ignition 1, to distinguish the correct power mode. The ignition 1 circuit is also routed to the Run/Crank relay for relay controlled power feeds during the appropriate power mode. The BCM, after determining the desired power mode, will activate the appropriate relays for that power mode. Run/Crank Relay The run/crank relay control circuit is connected to a constant ground and is switched by the ignition 1 circuit or the body control module (BCM). The BCM, will in lieu of the ignition switch position, activate the Run/Crank relay during a remote start event. The Run/Crank relay supplies a power signal to the following circuits, when the a Run or Crank power mode is selected: Automatic transmission shift indicator - Automatic transmission (A/T) - Switched power feeds to the BCM - Electronic brake control module (EBCM) - Electronic ignition module (spark control) - Electronic power steering module (EPS) - Fuel injectors - Powertrain control module (PCM) - Park neutral position (PNP) switch Accessory (ACC) Relay The adaptive cruise control (ACC) relay is energized when the Run or accessory power mode has been selected. The relay uses a Hot At All Times B+ power source derived from the underhood electrical center. The ACC relay is also energized by the body control module (BCM) to supply power during the retained accessory power (RAP) mode. The following devices are controlled by this relay: Inside rearview mirror - Heated seats - Power windows - Sunroof - Wiper washers switch Fail-Safe Operation Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the power mode master (PMM) fail to send a power mode message. The fail-safe plan covers those modules, using exclusively serial data control of power mode, as well as those modules with discrete ignition signal inputs. Serial Data Messages The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid power mode master (PMM) message until they can check for the engine run flag status on the serial data circuits. If the PMM fails, the modules monitor the serial data circuit for Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6245 the engine run flag serial data. If the engine run flag serial data is True, indicating that the engine is running, the modules fail-safe to RUN. In this state, the modules and their subsystems can support all operator requirements. If the engine run flag serial data is False, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Discrete Ignition Signals Those modules that have discrete ignition signal inputs, also remain in the state dictated by the last valid power mode master (PMM) message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, battery positive voltage, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 volts, the modules will fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. BCM Wake-Up/Sleep States The body control module (BCM) is able to control or perform all of the BCM functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system functions has stopped, and the BCM has become idle again. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors for these inputs during the sleep state, where the BCM is able to detect switch transitions that cause the BCM to wake-up when activated or deactivated. Multiple switch inputs are needed in order to sense both the insertion of the ignition key and the power mode requested. The BCM will enter a wake-up state, if any of the following wake-up inputs are detected: Activity on the serial data line - Detection of a battery disconnect and reconnect condition - Headlamps are ON. - Ignition is turned ON. - Key-in-ignition switch - Park lamps are ON. - RFA message The BCM will enter a sleep state when all of the following conditions exist: The ignition switch is OFF. - No activity exists on the serial data line. - No outputs are commanded. - No delay timers are actively counting. - No wake-up inputs are present. If all these conditions are met, the BCM will enter a low power or sleep condition. This condition indicates that the BCM, which is the power mode master (PMM) of the vehicle, has sent an OFF or OFF-ASLEEP message to the other systems on the serial data line. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 6246 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The Radio uses an exclusive RAP message that can not be circumvented by any door but the drives door. The BCM then sends a serial data power mode message ending the RAP function. The radio is the only module that is controlled by the serial data circuits. RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) The body control module (BCM) keeps the accessory relay energized during all power modes, except Off-Awake and Crank. The devices powered by the accessory relay during the retained accessory power (RAP) power mode are the sunroof and windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6249 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Scan Tool Does Not Communicate with Low Speed GMLAN Device See: Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With Low Speed GMLAN Device - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6250 Steps 1-12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6251 Steps 13-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6252 Steps 1-12 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle serial data communications and the control modules operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by a module which acts as the power mode master (PMM) in order to determine the correct power mode. The module which is the PMM communicates the system power mode to all modules on the serial data lines. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6253 Steps 1-6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6254 Steps 7-14 The numbers below refer to the step numbers on the diagnostic table. 6. This step tests for battery voltage on the incorrect signal circuits. 7. This step tests for no battery voltage on the required signal circuits. 8. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 9. This step eliminates open circuits as the cause of the malfunction. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6255 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Accessory Relay Command: The scan tool displays the state of the accessory relay command. Battery Voltage Signal: The scan tool displays the vehicle voltage. Ignition Mode Switch: The scan tool displays the ignition switch voltage signal. This signal is derived from the ignition Off/Run/Crank circuit. Ignition Switch Accessory: The scan tool displays the state of the ignition switch accessory circuit. Ignition Switch Run/Crank: The scan tool displays the state of the ignition switch Run/Crank circuit. Key In Ignition Cylinder: The scan tool displays whether or not the key is in the ignition cylinder. Power Mode: The scan tool displays the vehicle power mode. Run Relay Command: The scan tool displays the state of the Run relay. Run Crank Relay Command: The scan tool displays the state of the Run Crank relay. Vehicle Control Systems Data BCM Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. A new body control module (BCM) must be programmed with the proper regular production option (RPO) configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. The Tech 2 software will automatically prompt you with the RPO available for the vehicle. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the Vehicle Control Systems in Computer/Integrating Systems menu on the scan tool to program the BCM. Select Module Replacement/Setup and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passkey 3 Programming Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passkey 3 Programming procedure. Perform the Passkey 3 Programming Procedure if any of the following components have been replaced: The BCM - The powertrain control module (PCM)Refer to Programming Theft Deterrent System Components in Theft Deterrent for the proper procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 6258 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 6262 Throttle Actuator Control (TAC) Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 6271 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 6277 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Low Power/DTC's Set Bulletin No.: 07-06-04-003 Date: January 19, 2007 TECHNICAL Subject: LSJ, L61, LK5, L52, LL8 Engine-Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu 2006 Chevrolet Colorado, TrailBlazer 2006 GMC Canyon, Envoy 2006 HUMMER H3 2005-2006 Saturn ION, ION Red Line 2006 Saab 9-7X with ECOTEC(TM) 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F - RPOs LSJ, L61) or VORTEC(TM) 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138. Condition Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history: DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation DTC P2138 Accelerator Pedal Position (APP) Sensor 1-2 Correlation Cause This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM. Correction DO NOT replace the APP sensor. Inspect the PCM build date first. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-04-003 > Jan > 07 > Engine Controls - MIL ON/Low Power/DTC's Set > Page 6282 Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number. The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number: * 8 6 Y N AU K 1 5 3 2 5 0 R P N * If the PCM year and Julian dates are between 5182 and 5304,replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary. Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138. Warranty Information For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-060 > Sep > 05 > Engine, A/T Controls - Shared Diagnostic Trouble Codes Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-05-25-001 > Jan > 05 > Engine Controls - False DTC U2108 Set Engine Control Module: All Technical Service Bulletins Engine Controls - False DTC U2108 Set Bulletin No.: 05-05-25-001 Date: January 04, 2005 INFORMATION Subject: Information on a Falsely Set DTC U2108 in Engine Control Module (ECM) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) with Non-ABS Brake System (RPO J41) Built Prior to February, 2005 Technicians may observe DTC U2108 (ECM Lost Communications With ABS/TCS Control System), current or in history, stored in the ECM when the vehicle is connected to the Tech 2(R). This DTC is associated with ABS equipped vehicles. Because the above vehicle is not equipped with ABS, this may cause confusion. The ECM may falsely set a DTC U2108 in cars not equipped with ABS due to a software condition. A DTC U2108 will NOT illuminate a SES/MIL light. A code clear will only momentarily clear this DTC and will return to a current state almost immediately. No repairs to the vehicle are necessary as a result of a DTC U2108. DO NOT REPLACE THE BCM OR ECM. If the SES/MIL light is illuminated with a DTC U2108 present, look for additional DTCs causing the condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 6296 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 6297 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 6303 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 6304 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 6305 Engine and Transmission Modules Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Engine Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Powertrain Control Module (PCM) C3 (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6391 - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire). WARM-UP CYCLE The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCs) The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition) Indicates that this DTC failed during the present ignition cycle. Last Test Fail Indicates that this DTC failed the last time the test ran. MIL Request Indicates that this DTC is currently requesting the malfunction indicator lamp (MIL). This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear) Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History Indicates that the DTC is stored in the powertrain control module (PCM) History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear) DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6392 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The engine knock sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 6393 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) is the control center for the throttle actuator control (TAC) system. The PCM determines the drivers intent and then calculates the appropriate throttle response. The PCM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 6394 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. IMPORTANT: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change. 2. Disconnect the negative battery cable. 3. Disconnect the 3 powertrain control module (PCM) harness connectors from the PCM, noting proper orientation. 4. Use the retaining tab to release the PCM from the underhood junction block bracket. INSTALLATION PROCEDURE 1. Use the retaining tab to secure the PCM, when installing the PCM to the underhood junction block bracket. 2. Connect the PCM harness connectors to the PCM. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6399 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6400 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 6481 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Top Left Side of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 6485 Barometric Pressure Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 6486 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor harness connector. 2. Remove the BARO sensor bracket and bolt. 3. Remove the BARO sensor (2). INSTALLATION PROCEDURE 1. Install the BARO sensor (2). 2. Install the BARO sensor bracket and bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the BARO sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 6490 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 6491 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6572 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6573 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 6574 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 6578 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 6579 Clutch Pedal Position (CPP) Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6583 Top Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6584 Engine Coolant Temperature (ETC) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6585 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the engine coolant temperature ECT sensor electrical connector. 4. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent. 2. Install the ECT sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 6586 Tighten the ECT sensor to 22 N.m (16 lb ft). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 6667 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 6670 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The powertrain control module (PCM) sends the fuel level information via the GMLAN serial data circuit to the body control module (BCM). The BCM sends the GMLAN message to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 6674 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the fuel pump module assembly. 2. Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl. 3. Disconnect the fuel level sensor electrical connector from the pump module. 4. Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module. 5. Carefully slide the level sensor the rest of the way off of the pump module. INSTALLATION PROCEDURE 1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. 2. Secure the retaining tab (2) on the sensor into the slot on the pump module bowl. 3. Connect the fuel level sensor electrical connector to the pump module. 4. Install the fuel level sensor wiring harness to the molded-in tab (1) on the pump module bowl. 5. Install the fuel pump module assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6678 Fuel Tank Pressure (FTP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6679 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6680 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4. Carefully use the screwdrivers to lift and release the sensor from the fuel pump module. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 6681 1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor grommet is fully seated to the pump module. 2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 6685 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 6686 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor harness connector. 2. Remove the IAT sensor bolt. 3. While twisting the IAT sensor (3), pull the sensor from the engine. INSTALLATION PROCEDURE 1. Press the IAT sensor (3) into the engine. 2. Install the IAT sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 3. Connect the IAT sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6766 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 6767 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Intake Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 6771 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (TMAP) REMOVAL PROCEDURE 1. Disconnect the temperature manifold absolute pressure (TMAP) sensor harness connector. 2. Remove the TMAP sensor from the intake manifold. 3. Inspect the seal for damage. IMPORTANT: If the TMAP sensor seal is damaged, the TMAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the TMAP sensor into the intake manifold. IMPORTANT: Use the new TMAP sensor seal provided with the new TMAP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the TMAP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Manifold Absolute Pressure (MAP) Sensor Replacement (TMAP) > Page 6774 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement (SCIP) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT (SCIP) REMOVAL PROCEDURE 1. Disconnect the supercharger inlet pressure (SCIP) sensor harness connector. 2. Remove the SCIP sensor (1) from the supercharger. 3. Inspect the seal for damage. IMPORTANT: If the SCIP sensor seal is damaged, the SCIP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the SCIP sensor (1) into the intake manifold. IMPORTANT: Use the new SCIP sensor seal provided with the new SCIP sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the SCIP sensor harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor from the engine oil cooler assembly. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the engine oil pressure sensor to the engine oil cooler assembly. ^ Tighten the oil pressure sensor to 22 Nm (16 ft. lbs.). 2. Connect the engine oil pressure sensor electrical connector. 3. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Rear of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 6781 HO2S 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6857 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6858 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) - 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6859 Heated Oxygen Sensor (HO2S) - 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 1 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor using J 39194-C. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6862 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6863 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Position 2 HEATED OXYGEN SENSOR REPLACEMENT - POSITION 2 TOOLS REQUIRED J 39194-C Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel drive shaft heat shield. 3. Note the routing of the heated oxygen sensor (HO2S) electrical harness. 4. Disconnect the HO2S electrical connector (2), in the engine compartment. 5. Carefully bend the edge of the channel on the LH side of the exhaust heat shield outboard, just enough to release the HO2S electrical harness (1). 6. Using the J 39194 carefully remove the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. - Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6864 7. Lower the HO2S electrical harness away from the underbody. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 24185279, or equivalent. 2. Carefully install the HO2S to the pipe. 3. Using the J 39194, or equivalent, tighten the HO2S. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten the HO2S to 41 N.m (30 lb ft). 4. Install the HO2S electrical harness into position as noted before removal. 5. Carefully bend the edge of the channel (1) on the LH side of the exhaust heat shield inboard, just enough to secure the HO2S electrical harness in the channel. IMPORTANT: Use care when securing the HO2S electrical harness into the channel on the exhaust heat shield, to not pinch the wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Position 1 > Page 6865 6. Connect the HO2S electrical connector (2). 7. Install the wheel drive shaft heat shield. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 6947 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 6948 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 6949 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 6950 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 6951 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed > Page 6956 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed Vehicle Speed Sensor: Service and Repair Getrag 5 Speed Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Pull up on the VSS in order to remove the VSS from the transaxle. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 6959 3. Install the VSS assembly. 4. Install the VSS retainer. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 12 Nm (8 ft. lbs.). 6. Connect the VSS connector to the VSS. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 6960 Vehicle Speed Sensor: Service and Repair MU3 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the left front wheel. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the retainer bolt. 4. Remove the retainer. 5. Remove the VSS. 6. Remove and discard the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid Saturn P/N 121019223. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 6961 3. Install the VSS retainer.Install the vehicle speed sensor (VSS) assembly. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS (2). 6. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 6962 Vehicle Speed Sensor: Service and Repair 4T40-E/4T45-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable from the battery negative terminal. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to the case. Installation Procedure 1. Clean and dry the vehicle speed sensor. 2. Notice: Install the vehicle speed sensor and the retaining bolt. ^ Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Remove the safety stands. 5. Lower the vehicle. 6. Connect the negative battery cable. ^ Tighten the terminal bolt to 15 Nm (11 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 7044 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 7045 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 7046 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 7047 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 7048 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Getrag 5 Speed > Page 7053 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed Vehicle Speed Sensor: Service and Repair Getrag 5 Speed Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Pull up on the VSS in order to remove the VSS from the transaxle. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 7056 3. Install the VSS assembly. 4. Install the VSS retainer. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 12 Nm (8 ft. lbs.). 6. Connect the VSS connector to the VSS. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 7057 Vehicle Speed Sensor: Service and Repair MU3 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the left front wheel. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the retainer bolt. 4. Remove the retainer. 5. Remove the VSS. 6. Remove and discard the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid Saturn P/N 121019223. 2. Install the new O-ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 7058 3. Install the VSS retainer.Install the vehicle speed sensor (VSS) assembly. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS retainer bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS (2). 6. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Getrag 5 Speed > Page 7059 Vehicle Speed Sensor: Service and Repair 4T40-E/4T45-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable from the battery negative terminal. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to the case. Installation Procedure 1. Clean and dry the vehicle speed sensor. 2. Notice: Install the vehicle speed sensor and the retaining bolt. ^ Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Remove the safety stands. 5. Lower the vehicle. 6. Connect the negative battery cable. ^ Tighten the terminal bolt to 15 Nm (11 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension Technical Service Bulletin # 08020 Date: 100113 Campaign - Catalytic Converter Warranty Extension SPECIAL COVERAGE Bulletin No.: 08020 Date: January 13, 2010 Subject: 08020 - SPECIAL COVERAGE ADJUSTMENT - EXTENDED CATALYTIC CONVERTER WARRANTY COVERAGE Models: 2004-2007 SATURN ION RED LINE 2005-2007 CHEVROLET COBALT SS EQUIPPED WITH 2.0L 4-CYLINDER (RPO LSJ) ENGINE Condition Some customers of 2004-07 model year Saturn ION Red Line; and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, may comment on illumination of the malfunction indicator lamp (MAL) and/or lack of engine power. This may be caused by failure of the catalytic converter. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers/retailers are to replace the catalytic converter. The repairs will be made at no charge to the customer. Customers should not be charged for performing a system check when it is determined that the catalytic converter is not the cause of the customer complaint. Labor code T5725 is provided to submit claims for such system checks. Any additional necessary diagnosis and repairs that are not related to the catalytic converter are NOT covered by this special coverage. The customer should be informed that any further service that is not covered by the new vehicle warranty will not be covered by this policy. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 14, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 14, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-07 model year Saturn ION and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, and built within the following VIN breakpoints: Important Dealers/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverages are displayed in the Applicable Warranties section. Parts Information GM: Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO). Saturn US Only: Due to the limited number of affected vehicles, Saturn will not be doing a pre-shipment of parts. Retailers should order parts as needed from Saturn Service Parts Operations (SSPO). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7069 Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Service Procedure The purpose of this field action bulletin is to determine if it is necessary to replace the catalytic converter on certain 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine. The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to Strategy Based Diagnosis in SI. Determine the condition of the catalytic converter. Refer to Symptom - Engine Exhaust and Restricted Exhaust in SI. - If diagnosis indicates that the catalytic converter must be replaced, replace the Catalytic Converter. Refer to Catalytic Converter Replacement in SI. - If diagnosis indicates that the catalytic converter does NOT require replacement, determine the cause of the customer-reported exhaust concern using the diagnostic service information in SI. Diagnostic time and service repairs for exhaust system components other than the catalytic converter are NOT covered by this field action. Diagnostic time and service repair work for exhaust system components other than the catalytic converter must be billed under warranty or customer pay. Customer Reimbursement 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For GM US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7070 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to replace the catalytic converter are to be submitted to the dealer prior to or by January 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for this condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form is included with the customer letter. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers/retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter January 2010 Dear General Motors Customer: As the owner of a 2004-07 model year Saturn ION Red Line or 2005-07 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with a 2.0L 4-cylinder supercharged engine, may have a condition where the malfunction indicator lamp illuminates, and/or there is a lack of engine power. This may be caused by failure of the catalytic converter. Do not take your vehicle to your GM dealer/retailer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the catalytic converter. If this condition occurs on your 2004-2007 model year Saturn ION Red Line or 2005-2007 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer/retailer. If you believe that your vehicle has the condition covered by this special coverage, you may want to contact your GM dealer/retailer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer/retailer to order parts if Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7071 they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by January 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer/retailer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 06-06-01-010A > Feb > 08 > Exhaust System - Catalytic Converter Precautions Catalytic Converter: All Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension Technical Service Bulletin # 08020 Date: 100113 Campaign - Catalytic Converter Warranty Extension SPECIAL COVERAGE Bulletin No.: 08020 Date: January 13, 2010 Subject: 08020 - SPECIAL COVERAGE ADJUSTMENT - EXTENDED CATALYTIC CONVERTER WARRANTY COVERAGE Models: 2004-2007 SATURN ION RED LINE 2005-2007 CHEVROLET COBALT SS EQUIPPED WITH 2.0L 4-CYLINDER (RPO LSJ) ENGINE Condition Some customers of 2004-07 model year Saturn ION Red Line; and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, may comment on illumination of the malfunction indicator lamp (MAL) and/or lack of engine power. This may be caused by failure of the catalytic converter. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers/retailers are to replace the catalytic converter. The repairs will be made at no charge to the customer. Customers should not be charged for performing a system check when it is determined that the catalytic converter is not the cause of the customer complaint. Labor code T5725 is provided to submit claims for such system checks. Any additional necessary diagnosis and repairs that are not related to the catalytic converter are NOT covered by this special coverage. The customer should be informed that any further service that is not covered by the new vehicle warranty will not be covered by this policy. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 14, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 14, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-07 model year Saturn ION and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, and built within the following VIN breakpoints: Important Dealers/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverages are displayed in the Applicable Warranties section. Parts Information GM: Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO). Saturn US Only: Due to the limited number of affected vehicles, Saturn will not be doing a pre-shipment of parts. Retailers should order parts as needed from Saturn Service Parts Operations (SSPO). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7081 Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Service Procedure The purpose of this field action bulletin is to determine if it is necessary to replace the catalytic converter on certain 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine. The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to Strategy Based Diagnosis in SI. Determine the condition of the catalytic converter. Refer to Symptom - Engine Exhaust and Restricted Exhaust in SI. - If diagnosis indicates that the catalytic converter must be replaced, replace the Catalytic Converter. Refer to Catalytic Converter Replacement in SI. - If diagnosis indicates that the catalytic converter does NOT require replacement, determine the cause of the customer-reported exhaust concern using the diagnostic service information in SI. Diagnostic time and service repairs for exhaust system components other than the catalytic converter are NOT covered by this field action. Diagnostic time and service repair work for exhaust system components other than the catalytic converter must be billed under warranty or customer pay. Customer Reimbursement 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For GM US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7082 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to replace the catalytic converter are to be submitted to the dealer prior to or by January 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for this condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form is included with the customer letter. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers/retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter January 2010 Dear General Motors Customer: As the owner of a 2004-07 model year Saturn ION Red Line or 2005-07 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with a 2.0L 4-cylinder supercharged engine, may have a condition where the malfunction indicator lamp illuminates, and/or there is a lack of engine power. This may be caused by failure of the catalytic converter. Do not take your vehicle to your GM dealer/retailer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the catalytic converter. If this condition occurs on your 2004-2007 model year Saturn ION Red Line or 2005-2007 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer/retailer. If you believe that your vehicle has the condition covered by this special coverage, you may want to contact your GM dealer/retailer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer/retailer to order parts if Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls: > 08020 > Jan > 10 > Campaign - Catalytic Converter Warranty Extension > Page 7083 they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by January 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer/retailer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 06-06-01-010A > Feb > 08 > Exhaust System - Catalytic Converter Precautions Catalytic Converter: All Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7089 Catalytic Converter: Service and Repair Catalytic Converter Replacement (LSJ) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the post catalytic converter heated oxygen sensor (HO2S). 3. Remove the catalytic converter pipe-to-exhaust manifold nuts. 4. Carefully separate the converter pipe from the exhaust manifold. 5. Lower the converter pipe to rest on the rear crossmember of the front suspension frame. 6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts. 7. Position the converter pipe forward and support the pipe. 8. Move the extension pipe rearward and down in order to separate the pipes. 9. Remove the catalytic converter pipe assembly from the vehicle. 10. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets. 11. Clean the flange surfaces of any remaining gasket material. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 7090 1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs. 2. Position the catalytic converter pipe assembly to the vehicle. 3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the catalytic converter pipe-to-exhaust extension pipe nuts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 5. Carefully install the converter pipe to the exhaust manifold. 6. Install the catalytic converter pipe-to-exhaust manifold nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 7. Install the post catalytic converter HO2S. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7095 Evaporative Emission (EVAP) Canister Purge Solenoid Valve Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7096 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID VALVE The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 7097 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the evaporative emission (EVAP) canister purge valve harness connector. 2. Disconnect the vacuum pipe from the EVAP canister purge valve. 3. Disconnect the purge pipe from the EVAP canister purge valve. 4. Remove the EVAP canister purge valve and bracket. 5. Remove the EVAP canister purge valve from the purge bracket. 6. Inspect for carbon release in the EVAP canister purge valve ports. INSTALLATION PROCEDURE 1. Install the EVAP canister purge valve on to the purge bracket. 2. Install the EVAP canister purge valve and bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the purge bracket nut to 8 N.m (71 lb in). 3. Connect the purge pipe to the EVAP canister purge valve. 4. Connect the vacuum pipe to the EVAP canister purge valve. 5. Connect the EVAP canister purge valve harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER FILTER REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Clean away any debris that may be present around the evaporative emission (EVAP) canister vent filter cover. 3. Carefully release the canister filter cover rear retaining tabs. 4. Carefully release the canister filter cover forward retaining tabs and remove the cover from the EVAP canister. 5. Remove the filter from the canister and discard the filter. 6. Remove the seal from the filter cover and discard the seal. 7. Clean the inside of the EVAP canister filter housing with a clean shop towel. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 7101 1. Install a NEW seal to the filter cover. Ensure that the seal is properly seated to the cover. 2. Install a NEW filter to the canister filter housing. 3. Install the filter cover to the EVAP canister. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams Evaporative Emissions (EVAP) Canister Vent Solenoid Valve Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 7106 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID VALVE The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 7107 Canister Vent Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the evaporative emission (EVAP) canister vent solenoid valve. 3. Clean away any debris that may be present around the EVAP canister vent valve. 4. Remove the EVAP canister retaining bolt (1). 5. Lower the EVAP canister. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 7108 6. Rotate the EVAP canister vent valve counterclockwise to release from the locked position. 7. Remove the vent valve from the EVAP canister. INSTALLATION PROCEDURE 1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to the released position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 7109 2. Rotate vent valve clockwise to secure into the locked position. 3. Install the EVAP canister and retaining bolt (1). NOTE: Refer to Fastener Notice in Service Precautions Tighten the bolt to 10 N.m (89 lb in). 4. Connect the electrical connector to the EVAP canister vent valve. 5. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Disconnect the crankcase ventilation hose from the camshaft cover. 2. Disconnect the crankcase ventilation hose from the air cleaner outlet duct. Installation Procedure 1. Connect the crankcase ventilation hose to the camshaft cover. 2. Connect the crankcase ventilation hose to the air cleaner outlet duct. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7123 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7124 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cracking times. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7125 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7126 Steps 7 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7131 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7132 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: Customer Interest Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 7141 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed Idle Speed: All Technical Service Bulletins Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 7147 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 7148 Idle Speed: By Symptom Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 7149 Disclaimer Technical Service Bulletin # 06-06-04-039 Date: 060810 Engine Controls - Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 7150 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 7151 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the connector position assurance (CPA) from the accelerator pedal position (APP) sensor connector. 2. Disconnect the APP sensor harness connector. 3. Remove the APP assembly attachment bolts from the brake pedal assembly. 4. Remove the APP assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 7155 1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the vehicle. 3. Install the attachment bolts into the APP assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal position assembly-to-brake bracket bolt to 9 N.m (80 lb in). 4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt, then pull back to confirm engagement. 5. Install the APP sensor connect CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7159 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7160 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Intake Duct Replacement AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the left front tire and wheel. 2. Remove the left front fender liner. 3. Remove the air cleaner intake duct assembly push-in fasteners. 4. Remove the air cleaner intake duct assembly bolt. 5. Remove the intake duct assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the intake duct assembly. 2. Install the intake duct assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb ft). 3. Install the intake duct assembly push in fasteners. 4. Install the left front fender liner. 5. Install the left front tire and wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 7166 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly air duct at the outlet duct clamp 1. 2. Loosen the outlet duct clamp 2 at the throttle body. 3. Remove the air outlet duct. INSTALLATION PROCEDURE 1. Install the air outlet duct. 2. Install the air outlet duct clamps 1 and 2. 3. Tighten the air outlet duct clamps 1 and 2. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Intake Duct Replacement > Page 7167 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7176 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7182 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 7183 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Loosen the air cleaner cover screws (1). 3. Remove the air cleaner cover (2). 4. Remove the air cleaner filter from the air cleaner housing (3). INSTALLATION PROCEDURE 1. Install the air cleaner filter into the air cleaner housing. 2. Install the air cleaner cover to the air cleaner housing. 3. Install the air cleaner housing cover screws (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 7184 NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air cleaner housing screws to 3 N.m (27 lb in). 4. Install the air cleaner assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7265 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7270 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7271 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7272 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7273 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7274 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7275 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7276 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 7277 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 7278 Fuel: Specifications GASOLINE OCTANE Use premium unleaded gasoline with a posted octane of 91 or higher for best performance. You may also use middle grade or regular unleaded gasoline rated at 87 octane or higher, but your vehicle's acceleration may be slightly reduced. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. GASOLINE SPECIFICATIONS It is recommended that gasoline meet specifications which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm. Gasoline meeting these specifications could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the "Auto Makers' Choice" label on the pump. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasoline contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasoline that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. TEST PROCEDURE 1. Test the fuel composition using J 44175 Fuel Composition Tester and J 44175-3 Instruction Manual. 2. If water appears in the fuel sample, clean the fuel system. Refer to Fuel System Cleaning. Fuel Composition Test Examples 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 4. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Refer to Fuel System Cleaning. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) > Page 7281 Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (Without Special Tool) ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL) TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz). Install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Fuel System - Fuel Cap Tether Availability Fuel Filler Cap: Technical Service Bulletins Fuel System - Fuel Cap Tether Availability Bulletin No.: 05-06-04-050 Date: August 17, 2005 INFORMATION Subject: Fuel Cap Tether (Strap) Retainer Available for Service Use Models: 2005-2006 Buick Terraza 2005-2006 Chevrolet Cobalt, Uplander 2005-2006 Pontiac Montana SV6, Pursuit (Canada Only) The fuel filler cap tether (strap) retainer is now available for service as a separate part. The retainer was formerly available only as part of the fuel filler cap. If the fuel filler cap tether (strap) binds and breaks the retainer holding the cap on the vehicle, replace only the retainer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 7286 Fuel Filler Cap: Description and Operation FUEL FILLER CAP NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7292 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 7293 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Turn the ignition OFF. CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 2. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Loosen the fuel filler cap to relieve the fuel tank vapor pressure. 4. Remove the cap from the fuel pressure service port. 5. Remove the engine identification cover nuts and cover. 6. Connect the J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage. 7. Install the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 8. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. The fuel connections are now safe for servicing. 9. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage. 10. Disconnect the J 34730-1A from the fuel pressure service port connection. 11. Drain any fuel remaining in the gage into an approved fuel container. 12. Install the cap to the fuel pressure service port. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7302 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7303 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7304 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7305 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7311 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7312 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7313 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7314 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 Fuel Injector: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 Fuel Injector: Connector Views Fuel Injector 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 Fuel Injector 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Fuel Injector 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Fuel Injector 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 7404 Fuel Injector: Description and Operation FUEL INJECTORS The fuel injector assembly is a solenoid device controlled by the control module that meters pressurized fuel to a single engine cylinder. The control module energizes the high-impedance, 12 ohm, injector solenoid (4) to open a normally closed ball valve (1). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate (3) at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. TEST Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7407 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Actual Results May Vary) The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7408 Steps 1 - 5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7409 Steps 6 - 8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7410 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Actual Results May Vary) The scan tool is first used to energize the fuel pump relay. The scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7411 Steps 1 - 5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7412 Steps 6 - 8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7413 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis FUEL INJECTOR CIRCUIT DIAGNOSIS CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 7414 Steps 1 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 7415 Fuel Injector: Service and Repair FUEL INJECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel rail. 2. Remove the fuel injector retainer clip (3). 3. Remove the fuel injectors (5) from the fuel rail. 4. Remove and discard the fuel injector O-rings (4, 7). IMPORTANT: Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly. INSTALLATION PROCEDURE 1. Install the O-rings on the fuel injector (4, 7). IMPORTANT: Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil. 2. Install the fuel injector clip (3) on the fuel injector (5). 3. Install the fuel injector in the fuel rail with the connector facing upward. IMPORTANT: The fuel injector will click when the injector is installed correctly. 4. Install the fuel rail. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting, if applicable. 3. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. 5. Pull the connection apart. 6. Using a clean shop towel, wipe off the male pipe end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7421 1. Apply a few drops of clean engine oil to the male pipe end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting, if applicable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7422 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) (Press Release) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. Important: There are several types of plastic collar fuel and evaporative emission quick connect fittings that may be used on this vehicle. - Bartholomew (1) - Q release (2) - Squeeze to release (3) - Sliding retainer (4) - Push down TI (5) The following instructions apply to all of these types of fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 2. Using compressed air, blow any dirt out of the quick connect fitting. 3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7423 4. This step applies to the Q release type connectors ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. 6. This step also applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7424 7. This step applies to the Sliding retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. the tab will only move in one direction. 8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tabs indicated by the arrow. 9. Pull the connection apart. 10. Wipe off the male pipe end using a clean shop towel. 11. Inspect both ends of the fitting for dirt and burrs. 12. Clean or replace the components as required. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 7425 2. Push both sides of the quick connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR The fuel pressure regulator is contained in the fuel sender assembly. The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. Fuel pressure is controlled by a pressure balance across the regulator. The fuel system pressure is constant and is no longer a function of engine load or manifold vacuum. A software bias compensates the injector on-time based on the signal from the manifold absolute pressure (MAP) sensor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL PULSE DAMPENER The fuel pulse dampener attaches inside a housing on the fuel rail assembly. The fuel pulse dampener is diaphragm-operated, with fuel pump pressure on one side and with spring pressure on the other side. The function of the dampener is to dampen the fuel pump pressure pulsations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Remove the cap from the fuel pressure service port connection. 2. Connect the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 3. Turn the ignition ON, with the engine OFF. 4. Place the bleed hose of the J 34730-1A into an approved fuel container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 5. Open the bleed valve on the J 34730-1A in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the J 34730-1A. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Ensure the fuel pump is OFF. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7438 2. Place the bleed hose of the J 34730-1A into an approved fuel container. 3. Open the bleed valve on the J 34730-1A in order to bleed the fuel system pressure. 4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage. 5. Remove the J 34730-1A from the fuel pressure service connection. 6. Drain any fuel remaining in the J 34730-1A into an approved fuel container. 7. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 8. Install the cap on the fuel pressure service connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7439 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cracking times. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7440 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7441 Steps 7 - 13 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the cylinder head. The fuel rail assembly performs the following functions: - Positions the injectors in the cylinder head - Distributes fuel evenly to the injectors - Integrates the fuel pulse dampener into the fuel metering system Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7526 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant overflow pipe. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe. 4. Remove the fuel rail attaching studs. 5. Remove the fuel rail using the following procedure: 1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports. 2. Rotate the fuel rail in order to position the injectors downward. 3. Remove the fuel rail. IMPORTANT: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips. 6. Disconnect the fuel injector harness connectors. 7. Remove the fuel injectors. INSTALLATION PROCEDURE 1. Install the fuel injectors. 2. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place. 3. Install the fuel rail using the following procedure: 1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 7527 2. Align the injectors by rotating the fuel rail forward. 3. Carefully push the fuel injectors into the cylinder head ports. IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold. 4. Install the fuel rail attaching studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the fuel rail studs to 10 N.m (89 lb in). 5. Install the fuel supply pipe. Using a backup wrench on the fuel rail tighten the fuel supply pipe to 14 N.m (10 lb ft). 6. Install the coolant overflow pipe. Tighten the pipe bolt to 8 N.m (71 lb in). 7. Connect the negative battery cable. 8. Inspect for fuel leaks using the following procedure: 1. Turn ON the ignition, with the engine OFF for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition. 4. Inspect for fuel leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL FEED PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel injection system. The fuel pipe consists of 3 sections: - The rear fuel pipe is located from the top of the fuel tank to the chassis fuel pipe. The rear fuel pipe is constructed of nylon. - The chassis fuel pipe is located under the vehicle and connects the rear fuel pipe to the engine compartment fuel pipe. The chassis fuel pipe is constructed of galvanized aluminum. - The engine compartment fuel pipe connects the chassis fuel feed pipe to the fuel rail. The engine compartment fuel pipe is constructed of steel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment FUEL HOSE/PIPES REPLACEMENT - ENGINE COMPARTMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. 4. Use a back up wrench on the fuel rail and disconnect the fuel feed pipe. 5. Remove the fuel feed pipe fastener located on the engine. 6. Remove the engine fuel feed pipe. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7533 1. Install the fuel feed pipe to the fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. Using a backup wrench on the fuel rail tighten the fuel feed pipe to 14 N.m (10 lb ft). 2. Install the engine fuel feed pipe fastener located on the engine. Tighten the fuel feed pipe fastener to 10 N.m (89 lb in). 3. Connect the engine fuel feed pipe to the chassis fuel flex hose. 4. Connect the negative battery cable. 5. Inspect for leaks using the following procedure: 1. With the engine OFF, turn ON the ignition for 2 seconds. 2. Inspect for fuel leaks. 3. Turn the ignition OFF. 4. With the engine OFF, turn ON the ignition for 2 seconds. 5. Inspect for fuel leaks. 6. Turn the ignition OFF. 6. Install the engine cover and nuts. Tighten the nuts to 10 N.m (89 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7534 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the pipe retaining clip (1) from the fuel feed pipe. 3. Disconnect the fuel feed pipe from the engine fuel rail. 4. Cap or plug the fuel pipe and the engine fuel rail to prevent contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the evaporative emission (EVAP) canister for pipe removal access. 7. Disconnect the fuel filter from the engine feed fuel pipe (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7535 8. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs. 9. Release the pipe retainers (1) from the vehicle underbody. 10. Remove the fuel feed pipe from the pipe retainers. 11. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe. 12. Remove the fuel feed pipe from the vehicle. INSTALLATION PROCEDURE 1. Position the fuel feed pipe to the vehicle. 2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position. 3. Install the remainder of the pipe into position. 4. Install the fuel feed pipe to the pipe retainers. 5. Secure the pipe retainers (1) to the vehicle underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7536 6. Install the rear brake hose brackets to the body studs and install the rear brake hose bracket retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nuts to 10 N.m (89 lb in). 7. Connect the fuel filter to the engine feed fuel pipe (1). 8. Install the EVAP canister. 9. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7537 10. Remove the caps or plugs from the fuel pipe and the engine fuel rail. 11. Connect the fuel feed pipe to the engine fuel rail. 12. Install the pipe retaining clip (1) to the fuel feed pipe. 13. Connect the negative battery cable. 14. Inspect for fuel leaks using the following procedure: 1. Turn ON the ignition, with the engine OFF for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed Pipes Fuel Supply Line: Description and Operation Fuel Feed Pipes FUEL FEED PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel injection system. The fuel pipe consists of 3 sections: - The rear fuel pipe is located from the top of the fuel tank to the chassis fuel pipe. The rear fuel pipe is constructed of nylon. - The chassis fuel pipe is located under the vehicle and connects the rear fuel pipe to the engine compartment fuel pipe. The chassis fuel pipe is constructed of galvanized aluminum. - The engine compartment fuel pipe connects the chassis fuel feed pipe to the fuel rail. The engine compartment fuel pipe is constructed of steel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Feed Pipes > Page 7542 Fuel Supply Line: Description and Operation Nylon Fuel Pipes NYLON FUEL PIPES CAUTION: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment FUEL HOSE/PIPES REPLACEMENT - ENGINE COMPARTMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. 4. Use a back up wrench on the fuel rail and disconnect the fuel feed pipe. 5. Remove the fuel feed pipe fastener located on the engine. 6. Remove the engine fuel feed pipe. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7545 1. Install the fuel feed pipe to the fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. Using a backup wrench on the fuel rail tighten the fuel feed pipe to 14 N.m (10 lb ft). 2. Install the engine fuel feed pipe fastener located on the engine. Tighten the fuel feed pipe fastener to 10 N.m (89 lb in). 3. Connect the engine fuel feed pipe to the chassis fuel flex hose. 4. Connect the negative battery cable. 5. Inspect for leaks using the following procedure: 1. With the engine OFF, turn ON the ignition for 2 seconds. 2. Inspect for fuel leaks. 3. Turn the ignition OFF. 4. With the engine OFF, turn ON the ignition for 2 seconds. 5. Inspect for fuel leaks. 6. Turn the ignition OFF. 6. Install the engine cover and nuts. Tighten the nuts to 10 N.m (89 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7546 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the pipe retaining clip (1) from the fuel feed pipe. 3. Disconnect the fuel feed pipe from the engine fuel rail. 4. Cap or plug the fuel pipe and the engine fuel rail to prevent contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the evaporative emission (EVAP) canister for pipe removal access. 7. Disconnect the fuel filter from the engine feed fuel pipe (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7547 8. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs. 9. Release the pipe retainers (1) from the vehicle underbody. 10. Remove the fuel feed pipe from the pipe retainers. 11. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe. 12. Remove the fuel feed pipe from the vehicle. INSTALLATION PROCEDURE 1. Position the fuel feed pipe to the vehicle. 2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position. 3. Install the remainder of the pipe into position. 4. Install the fuel feed pipe to the pipe retainers. 5. Secure the pipe retainers (1) to the vehicle underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7548 6. Install the rear brake hose brackets to the body studs and install the rear brake hose bracket retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nuts to 10 N.m (89 lb in). 7. Connect the fuel filter to the engine feed fuel pipe (1). 8. Install the EVAP canister. 9. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 7549 10. Remove the caps or plugs from the fuel pipe and the engine fuel rail. 11. Connect the fuel feed pipe to the engine fuel rail. 12. Install the pipe retaining clip (1) to the fuel feed pipe. 13. Connect the negative battery cable. 14. Inspect for fuel leaks using the following procedure: 1. Turn ON the ignition, with the engine OFF for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation Fuel Filler Hose: Description and Operation FUEL FILL PIPE The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 7554 Fuel Filler Hose: Service and Repair FILLER TUBE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the fuel fill cap. 2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. 3. Remove the fuel filler pocket. 4. Remove the fuel filler pipe assembly upper retaining bolt. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Disconnect the evaporative emission (EVAP) vent pipe (1) from the EVAP canister. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 7555 7. Loosen the fuel filler hose clamp (1) at the fuel tank. 8. Remove the fuel filler pipe assembly lower retaining bolt. 9. Disconnect the fuel filler hose from the fuel tank. 10. Remove the fuel filler pipe assembly. INSTALLATION PROCEDURE 1. Install the fuel filler pipe assembly into position on the vehicle. 2. Connect the fuel filler hose to the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 7556 3. Install the fuel filler pipe assembly lower retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 4. Tighten the fuel filler hose clamp (1) at the fuel tank. Tighten the clamp to 4.5 N.m (40 lb in). 5. Connect the EVAP vent pipe (1) to the EVAP canister. 6. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 7557 7. Install the fuel filler pipe assembly upper retaining bolt. Tighten the bolt to 10 N.m (89 lb in). 8. Install the fuel filler pocket. 9. Refill the fuel tank. 10. Install the fuel fill cap. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: Customer Interest Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 7566 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 7572 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7573 Fuel Pump and Sender Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7574 Fuel Gauge Sender: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fill limit vent valve - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel pump - The fuel pressure regulator - The fuel strainer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7575 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED - SA9156E Fuel Tank Lock Ring Remover - J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank. 2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer. 3. Release the fuel pump module electrical harness from the retaining slot on the tank. 4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 5. Using the SA9156E, or J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7576 6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness. 7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank. 9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container. 10. Remove and discard the fuel pump module-to-fuel tank seal (1). IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7577 1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank. 3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly. 4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 7578 5. Using the SA9156E, or J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring. IMPORTANT: Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots. 6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor. 7. Secure the fuel pump module electrical harness into the retaining slot on the tank. 8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer. 9. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Pump and Sender Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 7582 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED - SA9156E Fuel Tank Lock Ring Remover - J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank. 2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer. 3. Release the fuel pump module electrical harness from the retaining slot on the tank. 4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 5. Using the SA9156E, or J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 7583 6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness. 7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank. 9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container. 10. Remove and discard the fuel pump module-to-fuel tank seal (1). IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 7584 1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank. 3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly. 4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 7585 5. Using the SA9156E, or J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring. IMPORTANT: Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots. 6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor. 7. Secure the fuel pump module electrical harness into the retaining slot on the tank. 8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer. 9. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7630 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7631 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7632 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7633 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7634 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7635 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7636 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7637 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7638 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7639 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7640 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7641 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7642 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7643 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7644 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7645 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7646 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7647 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7649 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair AIR CLEANER OUTLET RESONATOR REPLACEMENT REMOVAL PROCEDURE 1. Loosen the air cleaner assembly fresh air duct to resonator clamp. 2. Loosen the outlet resonator clamps. 3. Remove the air outlet resonator. INSTALLATION PROCEDURE 1. Install the air outlet resonator. 2. Tighten the air outlet resonator clamps. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the clamps to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7672 Accelerator Pedal Position (APP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7673 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors each with 3 circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The powertrain control module (PCM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the PCM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is near the low reference and increases as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near the 5-volt reference and decreases as the pedal is actuated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Mass Air Flow (MAF) Inlet Air Temperature (IAT) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 7754 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left front tire and wheel. 3. Remove the left front fender liner. 4. Remove the left front splash shield-engine. 5. Disconnect the electrical connector from the mass air flow (MAF) sensor. 6. Remove the 2 fasteners. 7. Remove the MAF sensor from the air cleaner housing. INSTALLATION PROCEDURE 1. Install the MAF sensor into the air cleaner housing. 2. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the 2 fasteners to 2 N.m (18 lb in). 3. Connect the MAF sensor electrical connector. 4. Install the left front splash shield-engine. 5. Install the left front fender liner. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7815 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7816 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7817 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7818 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7819 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7820 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7821 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7822 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7823 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7824 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7825 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7826 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7827 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7828 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7829 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7830 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Air Bypass Valve, Supercharger > Air Bypass Valve Actuator, Supercharger > Component Information > Service and Repair Air Bypass Valve Actuator: Service and Repair BYPASS VALVE ACTUATOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Gauge Supercharger > Component Information > Technical Service Bulletins > Instruments - Supercharger Boost Indicator Replacement Boost Gauge - Supercharger: Technical Service Bulletins Instruments - Supercharger Boost Indicator Replacement Bulletin No.: 05-08-49-025 Date: September 21, 2005 SERVICE MANUAL UPDATE Subject: Addition of Supercharger Boost Air Pressure Indicator Replacement Procedure Models: 2005 Chevrolet Cobalt This bulletin is being issued to add the Supercharger Boost Air Pressure Indicator Replacement procedure in the Instrument Panel, Gages, and Console sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Gauge Supercharger > Component Information > Technical Service Bulletins > Instruments - Supercharger Boost Indicator Replacement > Page 7842 Supercharger Boost Air Pressure Indicator Replacement Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Gauge Supercharger > Component Information > Technical Service Bulletins > Page 7843 Supercharger Boost Gage Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Gauge Supercharger > Component Information > Technical Service Bulletins > Page 7844 Boost Gauge - Supercharger: Service and Repair The content of this article reflects the changes found in TSB 05-08-49-025 Bulletin No.: 05-08-49-025 Date: September 21, 2005 SERVICE MANUAL UPDATE Subject: Addition of Supercharger Boost Air Pressure Indicator Replacement Procedure Models: 2005 Chevrolet Cobalt Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Gauge Supercharger > Component Information > Technical Service Bulletins > Page 7845 Supercharger Boost Air Pressure Indicator Replacement Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation Boost Solenoid: Description and Operation BOOST CONTROL SYSTEM DESCRIPTION OPERATION Bypass Valve Open Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7849 Bypass Valve Closed Supercharger boost pressure is regulated to prevent engine and drive train damage. When the engine is operating under high boost conditions, the powertrain control module (PCM) limits boost pressure to 83 kPa (12 psi). The PCM disables boost under the following conditions: When reverse gear is selected - When the engine coolant temperature (ECT) is excessively high - When drivetrain abuse is detected - When the vehicle is decelerating - If an intercooler pump failure is detected - If the intake air temperature (IAT) sensor 2 becomes excessively high - Under heavy load in first and second gear at engine speeds above 5,800 RPM The PCM controls boost pressure by using the boost control solenoid. The boost control solenoid is normally an open valve. Under most conditions, the PCM commands the boost control solenoid to operate at a 99-100 percent duty cycle. This keeps the solenoid valve closed and allows only inlet vacuum to control the position of the bypass valve. At idle, engine vacuum is applied to the upper side of the bypass valve actuator, counteracting spring tension to hold the bypass valve open. As engine load is increased, engine vacuum is decreased, causing the spring in the bypass valve actuator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7850 to overcome the applied vacuum, closing the bypass valve and allowing the boost pressure to increase. The bypass valve starts to close when the vacuum measures 250 mm Hg (10 in Hg) and is fully closed at 90 mm Hg (3.5 in Hg). When reduced boost pressure is desired, the PCM commands the boost control solenoid to operate at a 0 percent duty cycle. This opens the solenoid valve and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension, opening the bypass valve and recirculating excess boost pressure back into the supercharger inlet. RESULTS OF INCORRECT OPERATION An open boost control solenoid control circuit, an open ignition 1 circuit, or boost control solenoid valve stuck open will cause reduced engine power, especially during wide open throttle operation. The boost control solenoid control circuit shorted to ground, boost control solenoid valve stuck closed or a restriction in the boost source or signal hoses will cause full boost to be commanded at all times and a possible overboost condition during high engine load situations. A restriction in the vacuum signal hose to the bypass valve actuator or a stuck closed bypass valve will cause a rough idle and reduced fuel economy. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7851 Boost Solenoid: Testing and Inspection BOOST CONTROL SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION Supercharger boost pressure is regulated under certain conditions to prevent engine and drive train damage. When the engine is operating under high boost conditions, the powertrain control module (PCM) can limit boost pressure to 83 kPa (12 psi) or less. The PCM disables boost under the following conditions: When reverse gear is selected - When the vehicle is decelerating - If an intercooler pump failure is detected - If the intake air temperature (IAT) sensor 2 becomes excessively high - If the engine coolant temperature (ECT) becomes excessively high - Under heavy load in first and second gear at engine speeds above 5,800 RPM - When drivetrain abuse is detected The PCM controls boost pressure by using the boost control solenoid. The boost control solenoid is a normally open valve. Under most conditions, the PCM commands the boost control solenoid to operate at a 99-100 percent duty cycle. This keeps the solenoid valve closed and allows only inlet vacuum from the supercharger plenum to the bypass valve actuator to control the position of the bypass valve. At idle, engine vacuum is applied to the upper side of the bypass valve actuator, counteracting spring tension to hold the bypass valve open. When the engine load is increased, the engine vacuum is decreased, causing the spring in the bypass valve to overcome the diminishing applied vacuum, closing the bypass valve and allowing the boost pressure to increase. When reduced boost pressure is desired, the PCM commands the boost control solenoid to operate at a 0-98 percent duty cycle. This opens the solenoid valve and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension, opening the bypass valve, and recirculating excess boost pressure back into the supercharger inlet. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7852 Steps 1 - 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7853 Steps 7 - 16 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Boost Solenoid, Supercharger > Component Information > Description and Operation > Page 7854 Boost Solenoid: Service and Repair BOOST CONTROL SOLENOID REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the boost control solenoid connector. 2. Remove the boost control solenoid retaining bolt. 3. Remove the boost control solenoid (2). INSTALLATION PROCEDURE 1. Install the boost control solenoid (2) and bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 10 N.m (89 lb in). 2. Connect the boost control solenoid connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Description and Operation Intercooler: Description and Operation INTERCOOLER The supercharger has an integrated intercooler. Cooling the air enhances the effectiveness of the supercharger. The intercooler uses conventional coolant in a separate sealed system from the engine cooling system. The intercooler system has a radiator, a reserve tank/filler neck, a pressure cap, attaching hoses, and a pump capable of a 26 liters (7 gallons) per minute flow rate. The pump is commanded ON, by the control module, whenever the engine is running. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet Intercooler: Service and Repair Charge Air Cooler Hose Replacement - Outlet Charge Air Cooler Hose Replacement - Outlet ^ Tools Required GE-47622 Hose Clamp Pliers - SA9111E Constant Force Clamp Pliers Removal Procedure 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Place a drain pan under the front and the center of the vehicle. 2. Using the GE-47622, compress the outlet hose clamp at the charge air cooler. 3. Remove the outlet hose from the charge air cooler. 4. Remove the bolts from the charge air cooler reservoir. 5. Reposition the reservoir and the hose assembly up to gain access to the hose clamp. 6. Using the SA9111E, reposition the outlet hose clamp close to the opposite end of the hose. 7. Remove the charge air cooler outlet hose from the reservoir. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7860 1. Install the charge air cooler hose to the reservoir. 2. Reposition the hose clamp to secure the hose using the SA9111E. 3. Install the bolts to the charge air cooler reservoir. 4. Using the GE-47622, compress the hose clamp to secure the hose. 5. Install the charge air cooler outlet hose to the charge air cooler. 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7861 Intercooler: Service and Repair Coolant Recovery Reservoir Replacement - Charge Air Cooler Coolant Recovery Reservoir Replacement - Charge Air Cooler ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the bolts from the charge air cooler reservoir. 2. Using GE-47622 compress the outlet hose clamp at the charge air cooler. 3. Remove the outlet hose. 4. Reposition the hose and the reservoir up to allow access to the hose clamps. 5. Reposition the charge air cooler reservoir hose clamps using GE-47622. 6. Remove the charge air cooler reservoir hoses from the reservoir. Installation Procedure 1. Install the charge air cooler hoses to the reservoir. 2. Reposition the hose clamp to secure the hose using GE-47622. 3. Using GE-47622 compress the outlet hose clamp at the charge air cooler. 4. Install the outlet hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7862 5. Notice: Refer to Fastener Notice in Service Precautions. Install the charge air cooler reservoir bolts. ^ Tighten the bolts to 8 Nm (70 inch lbs.). 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7863 Intercooler: Service and Repair Charge Air Cooler Radiator Hose Replacement - Inlet Charge Air Cooler Radiator Hose Replacement - Inlet ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the GE-47622, compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator. 3. Remove the charge air cooler radiator inlet hose from the charge air cooler radiator. 4. Lower the vehicle. 5. Using the GE-47622, compress the charge air cooler radiator inlet hose clamp at the charge air cooler reservoir. 6. Remove the charge air cooler radiator inlet hose from the charge air cooler reservoir. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7864 1. Using the GE-47622, compress the charge air cooler radiator inlet hose clamp. 2. Install the charge air cooler radiator inlet hose to the charge air cooler reservoir. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Using the GE-47622, compress the charge air cooler radiator inlet hose clamp. 5. Install the charge air cooler radiator inlet hose to the charge air cooler radiator. 6. Lower the vehicle. 7. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7865 Intercooler: Service and Repair Radiator Replacement - Charge Air Cooler Radiator Replacement - Charge Air Cooler Removal Procedure 1. Drain the charge air cooling system. 2. Remove the pushpin fasteners from the air dam. 3. Remove the air dam. 4. Remove the condenser bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7866 5. Slide the condenser down to disengage the upper mounting tabs from the radiator. 6. Reposition the condenser to allow access to the charge air cooler radiator. 7. Remove the mounting bolt from the lower left side of the charge air cooler radiator. 8. Remove the mounting bolt from the lower right side of the charge air cooler radiator. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7867 9. Slide the charge air cooler down to disengage the upper mounting tab from the radiator. 10. Remove the charge air cooler radiator. Installation Procedure 1. Install the charge air cooler radiator. 2. Slide the charge air cooler up to engage the upper mounting tab to the radiator. 3. Install the mounting bolt to the lower right side of the charge air cooler radiator. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7868 4. Notice: Refer to Fastener Notice in Service Precautions. Install the mounting bolts to the lower left side of the charge air cooler radiator. ^ Tighten the bolts to 10 Nm (88 inch lbs.). 5. Slide the condenser up to engage the upper mounting tabs into the radiator. 6. Install the condenser bolts. ^ Tighten the bolts to 10 Nm (88 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Service and Repair > Charge Air Cooler Hose Replacement - Outlet > Page 7869 7. Install the air dam with the pushpin fasteners. 8. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Testing and Inspection Supercharger Coolant Pump: Testing and Inspection SUPERCHARGER INTERCOOLER RELAY DIAGNOSIS CIRCUIT DESCRIPTION The supercharger (SC) intercooler coolant relay is a normally open relay. The relay armature is held in the open position by spring tension. Ignition 1 voltage is supplied directly to the relay coil and to the armature contact, when the ignition is ON, or the engine is running. The powertrain control module (PCM) supplies the ground path to the relay coil control circuit, via an internal integrated circuit called an output driver module (ODM). When the engine is running, the PCM commands the relay ON, and the relay coil creates an electromagnetic field. This electromagnetic field overcomes the spring tension and pulls the armature contact into the stationary contact of the relay load circuit. The closing of the relay contacts allows current to flow from the battery to the SC intercooler coolant pump. When the ignition switch is turned to the OFF position, power is interrupted to the output driver module in the PCM, and the relay electromagnetic field collapses. This allows the spring tension to separate the relay armature contact from the relay load circuit contact, which interrupts current flow to the SC intercooler coolant pump. The SC intercooler coolant relay diagnosis is used to diagnose the load circuit supply voltage, the relay contacts, the relay load circuit which includes the SC intercooler coolant pump, and the ground for the SC intercooler coolant pump. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Testing and Inspection > Page 7873 Steps 1 - 9 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Testing and Inspection > Page 7874 Steps 10 - 15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet Supercharger Coolant Pump: Service and Repair Auxiliary Water Pump Hose Replacement - Inlet Auxiliary Water Pump Hose Replacement - Inlet ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler pump. 3. Remove the auxiliary water pump inlet hose from the charge air cooler pump. 4. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator. 5. Remove the auxiliary water pump inlet hose from the charge air cooler radiator. Installation Procedure 1. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 2. Install the auxiliary water pump inlet hose to the charge air cooler radiator. 3. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 4. Install the auxiliary water pump inlet hose to the charge air cooler pump. 5. Lower the vehicle. 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 7877 Supercharger Coolant Pump: Service and Repair Auxiliary Water Pump Hose Replacement Outlet Auxiliary Water Pump Hose Replacement - Outlet ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose at the charge air cooler pump. 3. Remove the outlet hose from the charge air cooler pump. 4. Lower the vehicle. 5. Using the GE-47622, compress the clamp at the auxiliary water pump outlet hose at the intercooler. 6. Remove the outlet hose from the charge air cooler radiator. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 7878 1. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose to secure the hose. 2. Install the outlet hose to the intercooler. 3. Using the GE-47622, compress the clamp to the auxiliary water pump outlet hose to secure the hose. 4. Install the outlet hose to the charge air cooler pump. 5. Lower the vehicle. 6. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 7879 Supercharger Coolant Pump: Service and Repair Coolant Pump Replacement - Charge Air Cooler Coolant Pump Replacement - Charge Air Cooler ^ Tools Required GE-47622 Hose Clamp Pliers Removal Procedure 1. Drain the charge air cooling system. 2. Using the GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler pump. 3. Remove the auxiliary water pump inlet hose from the charge air cooler pump. 4. Using the GE-47622, compress the auxiliary water pump outlet hose clamp at the charge air cooler pump. 5. Remove the auxiliary water pump outlet hose from the charge air cooler pump. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 7880 6. Disconnect the charge air cooler pump electrical connector. 7. Remove the charge air cooler pump mounting clamp bolts. 8. Remove the charge air cooler pump. Installation Procedure 1. Install the charge air cooler pump. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the mounting clamp bolts to the charge air cooler pump. ^ Tighten the bolts to 10 Nm (88 inch lbs.). 3. Connect the charge air cooler pump electrical connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Coolant Pump > Component Information > Service and Repair > Auxiliary Water Pump Hose Replacement - Inlet > Page 7881 4. Using the GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose. 5. Install the auxiliary water pump inlet hose to the charge air cooler pump. 6. Using the GE-47622, compress the auxiliary water pump outlet hose clamp to secure the hose. 7. Install the auxiliary water pump outlet hose to the charge air cooler pump. 8. Lower the vehicle. 9. Fill the cooling system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Supercharger Oil > Component Information > Specifications Supercharger Oil: Specifications SUPERCHARGER OIL The gears and ball bearings are lubricated by a synthetic oil. The oil reservoir is self-contained in the supercharger and does not rely on engine oil for lubrication. This oil reservoir is sealed for the life of the unit and is not serviceable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation Throttle Body: Description and Operation THROTTLE BODY ASSEMBLY The throttle assembly contains the following components: - The throttle blade - The throttle actuator motor - The throttle position (TP) sensor 1 and 2 The throttle body functions similar to a conventional throttle body with the following exceptions: - An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors are used to determine the throttle plate angle. The TP sensors provide the powertrain control module (PCM) with a signal voltage proportional to throttle plate movement. The TP sensor 1 signal voltage at closed throttle is near the 5-volt reference and decreases as the throttle plate is opened. The TP sensor 2 signal voltage at closed throttle is near the low reference and increases as the throttle plate is opened. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 7888 Throttle Body: Service and Repair THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 1. Remove the air cleaner outlet duct. 2. Disconnect the evaporative emission (EVAP) purge line. 3. Disconnect the throttle body control harness connector. 4. Remove the throttle body attaching bolts. 5. Remove the throttle body and gasket from the supercharger. INSTALLATION PROCEDURE 1. Inspect the throttle body gasket and replace if necessary. 2. Install the throttle body to the supercharger. 3. Install the throttle body attaching bolts. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 7889 Tighten the throttle body attaching bolts to 10 N.m (89 lb in). 4. Connect the throttle body control harness connector. 5. Connect the EVAP purge line. 6. Install the air cleaner outlet duct. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7936 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7937 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7938 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7939 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8011 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8012 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8013 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8014 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8015 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8049 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8050 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8051 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8067 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8068 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8069 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 8132 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8135 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Information not supplied by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Ignition Coil/module 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8142 Ignition Coil/Module 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8143 Ignition Coil/module 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8144 Ignition Coil/Module 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8145 Ignition Coil: Description and Operation IGNITION COIL/MODULE Each ignition coil/module has the following circuits: - An ignition voltage circuit - A ground - An ignition control (IC) circuit - A low reference circuit The PCM controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event. The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 8146 Ignition Coil: Service and Repair IGNITION COIL(S) REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the ignition coil connectors from the ignition coils. 2. Remove the retaining bolts from the ignition coils. 3. Remove the ignition coils from the engine. INSTALLATION PROCEDURE 1. Install the ignition coil. IMPORTANT: Make sure that the ignition coil seals are properly seated to the valve cover. 2. Install the ignition coil retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the ignition coil retaining bolts to 10 N.m (89 lb in). 3. Replace the ignition coil connectors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Ignition Coil/module 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8150 Ignition Coil/Module 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8151 Ignition Coil/module 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8152 Ignition Coil/Module 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8153 Ignition Control Module: Description and Operation IGNITION COIL/MODULE Each ignition coil/module has the following circuits: - An ignition voltage circuit - A ground - An ignition control (IC) circuit - A low reference circuit The PCM controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event. The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 8233 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 8234 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Ignition Coil/module 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8239 Ignition Coil/Module 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8240 Ignition Coil/module 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8241 Ignition Coil/Module 4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 8242 Ignition Control Module: Description and Operation IGNITION COIL/MODULE Each ignition coil/module has the following circuits: - An ignition voltage circuit - A ground - An ignition control (IC) circuit - A low reference circuit The PCM controls the individual coils by transmitting timing pulses on the IC circuit of each ignition coil/module to enable a spark event. The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plug electrode is tipped with platinum for long wear and higher efficiency. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Above The Transmission Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8249 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8250 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8251 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8254 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8255 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8256 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8257 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8258 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8259 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8260 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8261 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8262 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8263 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8264 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8265 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8267 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8268 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8269 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8270 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8271 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8274 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8275 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8276 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8277 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8278 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8279 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8280 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8285 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8286 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8287 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8296 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8297 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8298 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8299 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8300 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8301 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8302 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8303 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8304 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8305 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8310 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8311 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8313 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8314 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8315 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8316 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8317 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8318 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8319 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8320 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8321 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 Camshaft Position (CMP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8324 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built onto the exhaust camshaft sprocket. The CMP sensor provides four signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The CMP sensor is connected to the PCM by the following circuits: - A 5-volt circuit - A low reference circuit - A signal circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8325 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the underhood junction block. 3. Disconnect the electrical connector from the camshaft position (CMP) sensor. 4. Remove the CMP sensor studs. 5. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Rotate the crankshaft until number 4 piston is at top dead center (TDC) on the compression stroke. Refer to the crankshaft damper-to-front-cover timing marks. 2. Install the NEW camshaft position sensor housing seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 8326 3. Align the timing mark on the housing with the timing mark on the hex shaft. 4. Install the camshaft position sensor housing. 5. Install the camshaft position sensor housing studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the camshaft position sensor housing studs to 22 N.m (16 lb ft). 6. Install the underhood junction block. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Lower Front of the Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8361 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8362 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8363 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8364 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8365 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 Crankshaft Position (CKP) Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 8407 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a permanent magnet generator known as a variable reluctance sensor. The CKP sensor produces an AC voltage of varying amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC output depends on the crankshaft position and the battery voltage. The CKP sensor works in conjunction with a 58-tooth reluctor wheel attached to the crankshaft. As each reluctor wheel tooth rotates past the CKP sensor, the resulting change in the magnetic field creates an ON/OFF pulse 58 times per crankshaft revolution. The PCM processes the pulses to create a pattern that enables the PCM to determine the crankshaft position. The PCM can synchronize the ignition timing, the fuel injector timing, and the spark knock control based on the CKP sensor and the camshaft position (CMP) sensor inputs. The CKP sensor is also used to detect misfire and for tachometer display. The PCM learns the variations between all 58 teeth under different speed and load conditions to correctly detect misfires. The CKP sensor circuits consist of a signal circuit and a low reference circuit. The two wires are twisted together to prevent electromagnetic interference on the CKP sensor circuits. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 3. Using a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. The scan tool instructs you to perform the following procedures: 1. Accelerate to wide open throttle (WOT). 2. Release the throttle when the fuel cutoff occurs. 3. Observe the fuel cutoff specifications for the applicable engine. 4. Engine should not accelerate beyond the calibrated RPM value. 5. Release the throttle immediately if the value is exceeded. 6. Block the drive wheels. 7. Set the parking brake. 8. DO NOT apply the brake pedal. 9. Cycle the ignition from OFF to ON. 10. Apply and hold the brake pedal. 11. Start and idle the engine. 12. Turn the A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: The CKP sensor activity-If a CKP sensor condition exists, refer to the applicable DTC that set. - The camshaft position (CMP) signal activity-If a CMP signal condition exists, refer to the applicable DTC that set. - The engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Using the scan tool, enable the CKP system variation learn procedure. Perform the following procedure: 1. Accelerate to wide open throttle (WOT). 2. Release when the fuel cutoff occurs. 3. Test in progress. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator, and the engine responds to throttle position after the learn procedure is complete. 6. The scan tool displays Learn Status: Learned This Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in Vehicle DTC Information for the applicable DTC that set. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 8. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement - A PCM replacement - A crankshaft damper replacement - A crankshaft replacement - A CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 8410 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor (2). INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor (2) into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the CKP sensor bolt to 10 N.m (89 lb in). 4. Reconnect the CKP sensor electrical connector. 5. Install the starter. 6. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8424 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8425 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8426 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 8435 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8445 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8446 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8447 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 8456 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 Knock Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 Knock Sensor (KS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 8545 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION The KS system uses a flat response two-wire sensor. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The ECM receives the KS signal through a signal circuit. The KS ground is supplied by the ECM through a low reference circuit. The ECM learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The ECM uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the ECM only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The ECM will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the ECM, the KS wiring, the KS voltage output, or constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 8546 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... .................................... 25 - 30 Nm (18.4 - 22.1 lb ft) Spark Plug Gap ................................................ ............................................................................................................................................... 1 mm (0.04 in) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8550 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................... GM P/N 12787099 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8551 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8552 - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8553 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coils. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT coat the spark plugs with anti-seize compound. Over torquing could occur and damage to the cylinder head threads may Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 8554 result. Tighten the spark plugs to 20 N.m (15 lb ft). 3. Install the ignition coils. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8561 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8562 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8569 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8570 Shift Solenoid: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8571 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 8574 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8578 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8579 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 8586 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 8592 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 8593 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8598 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8607 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8608 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8609 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8615 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8616 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8617 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8621 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8622 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8623 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8624 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8625 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8629 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed PROM - Programmable Read Only Memory: Customer Interest Engine Controls Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 8645 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-06-04-033 > Jun > 06 > Engine Controls - SES Lamp ON/DTC P0171 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES Lamp ON/DTC P0171 Set Bulletin No.: 06-06-04-033 Date: June 21, 2006 TECHNICAL Subject: L61 Engine Malfunction Indicator Lamp (MIL)/Service Engine Soon (SES) Lamp Illuminated with DTC P0171 "Fuel Trim System Lean" Set (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS Supercharged 2006 Chevrolet HHR 2004-2006 Chevrolet Malibu 2005-2006 Pontiac Pursuit (Canada Only) 2004-2005 Saturn ION Redline 2005-2006 Saturn ION with Ecotec(TM) 2.0L or 2.2L I-4 Engine (VINs P, F - RPOs LSJ, L61) Condition Some customer may comment that the MIL/SES lamp is Illuminated. Further diagnostic investigation with a scan tool may reveal a DTC P0171 Fuel Trim System Lean. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct a variation in the Mass Air Flow Sensor. Correction DO NOT replace the MAF sensor, the ECM or any other parts. Important: ^ Chevrolet/Pontiac Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0171 concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-06-04-033 > Jun > 06 > Engine Controls - SES Lamp ON/DTC P0171 Set > Page 8650 For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Bulletin No.: 05-06-04-038D Date: April 13, 2006 TECHNICAL Subject: 2.0L LSJ Engine SES Lamp Illuminated with DTC P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" Set (Reprogram PCM) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with Supercharged 2.0L Four-Cylinder Engine (VIN P - RPO LSJ) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 05-06-04-038C (Section 06 - Engine). Condition Some customers may comment that the Service Engine Soon (SES) lamp is illuminated. Diagnostic Trouble Code (DTC) P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" may be set. Cause Under certain ambient engine temperature conditions, the thermostatically controlled engine coolant temperature may not reach the calibrated threshold in the allotted time frame that is programmed in the PCM. Correction Follow the steps outlined in the "Service Procedure" section of this bulletin to repair a false DTC P0128. Service Procedure Verify operation of the thermostat and cooling system. Refer to "DTC P0128" diagnostic in published Service Information. Before replacing the engine coolant thermostat and/or updating PCM calibration for repairing a false DTC P0128. Perform the following service procedures: 1. Observe the coolant temperature within the P0128 Freeze Frame. ^ If the engine coolant temperature is greater than 70.25°C (158.25°F) with DTC P0128, the PCM needs the updated calibration. Do not replace the engine coolant thermostat. ^ If the engine coolant temperature is less than 70.25°C (158.25°F) with DTC P0128, replace only the engine coolant thermostat. Important: Chevrolet Dealers: The PCM calibration is available to dealerships as part of TIS2000 incremental satellite update version 4.0, which was broadcast to dealers in April, 2006 or later. For the dealerships that use CDs, they were mailed out April, 2006 or later. Important: Saturn Retailers: Before installing the new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 4.0 2006 or later. Important: While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures. Important: Technician must select the "Reprogram" option in order to reprogram the PCM. 2. Reprogram the PCM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0128 concern. Refer to "Service Programming System (SPS)" in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 8655 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Fuel Gauge Inaccuracy Bulletin No.: 05-08-49-002A Date: January 28, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Fuel Gauge Accuracy and/or Fuel Gauge Fluctuation, Fuel Gauge Does Not Go To Full (Reprogram Engine Control Module (ECM)) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To January 17, 2005 Supercede: This bulletin is being updated to include the Correction information and a revised "built prior to" date. Please discard Corporate Bulletin Number 05-08-49-002 (Section 08 - Body). Condition Some customers may comment that the fuel gauge does not go to the full position when the fuel tank is full and/or that the fuel gauge has excessive fluctuating when the vehicle stops or accelerates suddenly. Correction Reprogram the ECM with a new service calibration released with TIS satellite data update version 1.75 on January 25, 2005 or newer. Refer to Service Programming System (SPS). Dealer Action Contact customers that were told they would be notified when a fix became available. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy > Page 8660 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Fluctuating/Unstable Idle Speed Bulletin No.: 06-06-04-039 Date: August 10, 2006 TECHNICAL Subject: Fluctuating, Unstable or Incorrect Engine Idle - LSJ (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt SS Supercharged 2004-2006 Saturn ION Redline with Ecotec(TM) 2.0L I-4 Engine (VIN P - RPO LSJ) Condition Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle Correction DO NOT replace the throttle body, the ECM or any other parts. Important: ^ Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. ^ Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-039 > Aug > 06 > Engine Controls - Fluctuating/Unstable Idle Speed > Page 8666 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-033 > Jun > 06 > Engine Controls - SES Lamp ON/DTC P0171 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC P0171 Set Bulletin No.: 06-06-04-033 Date: June 21, 2006 TECHNICAL Subject: L61 Engine Malfunction Indicator Lamp (MIL)/Service Engine Soon (SES) Lamp Illuminated with DTC P0171 "Fuel Trim System Lean" Set (Reprogram ECM) Models: 2005-2006 Chevrolet Cobalt, Cobalt SS Supercharged 2006 Chevrolet HHR 2004-2006 Chevrolet Malibu 2005-2006 Pontiac Pursuit (Canada Only) 2004-2005 Saturn ION Redline 2005-2006 Saturn ION with Ecotec(TM) 2.0L or 2.2L I-4 Engine (VINs P, F - RPOs LSJ, L61) Condition Some customer may comment that the MIL/SES lamp is Illuminated. Further diagnostic investigation with a scan tool may reveal a DTC P0171 Fuel Trim System Lean. No other driveability or performance concerns may be reported. Cause The most likely cause of this issue may be that the engine calibrations need to be updated to correct a variation in the Mass Air Flow Sensor. Correction DO NOT replace the MAF sensor, the ECM or any other parts. Important: ^ Chevrolet/Pontiac Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June 2006 or later. ^ Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later. ^ While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures ^ The technician must select the "Reprogram" option in order to reprogram the ECM. Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0171 concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-04-033 > Jun > 06 > Engine Controls - SES Lamp ON/DTC P0171 Set > Page 8671 For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls SES/MIL Lamp ON/DTC P0128 Stored Bulletin No.: 05-06-04-038D Date: April 13, 2006 TECHNICAL Subject: 2.0L LSJ Engine SES Lamp Illuminated with DTC P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" Set (Reprogram PCM) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with Supercharged 2.0L Four-Cylinder Engine (VIN P - RPO LSJ) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 05-06-04-038C (Section 06 - Engine). Condition Some customers may comment that the Service Engine Soon (SES) lamp is illuminated. Diagnostic Trouble Code (DTC) P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" may be set. Cause Under certain ambient engine temperature conditions, the thermostatically controlled engine coolant temperature may not reach the calibrated threshold in the allotted time frame that is programmed in the PCM. Correction Follow the steps outlined in the "Service Procedure" section of this bulletin to repair a false DTC P0128. Service Procedure Verify operation of the thermostat and cooling system. Refer to "DTC P0128" diagnostic in published Service Information. Before replacing the engine coolant thermostat and/or updating PCM calibration for repairing a false DTC P0128. Perform the following service procedures: 1. Observe the coolant temperature within the P0128 Freeze Frame. ^ If the engine coolant temperature is greater than 70.25°C (158.25°F) with DTC P0128, the PCM needs the updated calibration. Do not replace the engine coolant thermostat. ^ If the engine coolant temperature is less than 70.25°C (158.25°F) with DTC P0128, replace only the engine coolant thermostat. Important: Chevrolet Dealers: The PCM calibration is available to dealerships as part of TIS2000 incremental satellite update version 4.0, which was broadcast to dealers in April, 2006 or later. For the dealerships that use CDs, they were mailed out April, 2006 or later. Important: Saturn Retailers: Before installing the new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 4.0 2006 or later. Important: While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures. Important: Technician must select the "Reprogram" option in order to reprogram the PCM. 2. Reprogram the PCM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0128 concern. Refer to "Service Programming System (SPS)" in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 8676 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Fuel Gauge Inaccuracy Bulletin No.: 05-08-49-002A Date: January 28, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Fuel Gauge Accuracy and/or Fuel Gauge Fluctuation, Fuel Gauge Does Not Go To Full (Reprogram Engine Control Module (ECM)) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To January 17, 2005 Supercede: This bulletin is being updated to include the Correction information and a revised "built prior to" date. Please discard Corporate Bulletin Number 05-08-49-002 (Section 08 - Body). Condition Some customers may comment that the fuel gauge does not go to the full position when the fuel tank is full and/or that the fuel gauge has excessive fluctuating when the vehicle stops or accelerates suddenly. Correction Reprogram the ECM with a new service calibration released with TIS satellite data update version 1.75 on January 25, 2005 or newer. Refer to Service Programming System (SPS). Dealer Action Contact customers that were told they would be notified when a fix became available. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy > Page 8681 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8688 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8689 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8696 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8697 Shift Solenoid: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8698 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 8701 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8705 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8706 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8712 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8713 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8720 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8721 Shift Solenoid: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8722 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 8725 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8729 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8730 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Replacement Low/Reverse Servo Assembly Replacement Removal Procedure 1. Caution: Refer to Vehicle Lifting Caution in Service Precautions. Raise the vehicle. Support the vehicle. 2. Remove the oil pan and filter. 3. Remove the oil feed pipes. 4. Remove the three low/reverse band servo cover bolts, the servo and the spring. 5. Disassemble, clean and inspect the low/reverse servo assembly. Installation Procedure 1. Assemble the low/reverse servo. 2. Notice: Install the low/reverse band servo cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil feed pipe. 4. Install the oil filter and pan. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Fill the transmission. 8. Inspect the transmission fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 8735 Band Apply Servo: Service and Repair Intermediate/Fourth Servo Assembly Replacement Intermediate/Fourth Servo Assembly Replacement Removal Procedure 1. Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. Position the vehicle on a hoist and raise the vehicle. 2. Remove the oil pan. 3. Remove the oil level control valve. Pull the valve straight down. Do not pry on the valve. 4. Remove the oil filter and oil filter O-ring seal. The seal may stay in the case when the filter is removed. 5. Important: Do not score or damage the transaxle case when removing the filter neck seal. Using a chisel, indent the top of the filter neck seal to relax the press fit. 6. Remove the filter neck seal from the transaxle case and discard. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 8736 7. Remove the intermediate/4th servo assembly bolts. 8. Remove the intermediate/4th servo assembly. Disassembly Procedure 1. Remove the piston and pin assembly from the servo cover. 2. Remove the snap ring from the servo pin. 3. Remove the piston and the servo cushion springs from the servo pin. 4. Remove the servo piston seals from the servo cover. 5. Discard the servo piston seals. Do not reuse the servo piston seals. 6. Inspect all components for damage. 7. Inspect the fluid feed holes for obstructions. 8. Inspect the bolt hole threads for debris and stripping. 9. Inspect the seal grooves for damage. 10. Clean and dry each component. Assembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 8737 1. Install the servo cushion springs and the servo piston onto the servo pin. 2. Install the snap ring onto the servo pin in order to retain the springs and piston. 3. Install the new seals onto the servo piston and the servo cover. 4. Install the servo piston assembly into the servo cover. Lubricate the piston seals with transaxle fluid in order to aid in assembly. Installation Procedure 1. Install the servo return spring into the transaxle case. 2. Install the servo return spring into the transaxle case. 3. Notice: Important: Hand start and tighten servo cover bolts evenly to prevent damage to servo cover bore. Hand start and install the servo cover bolts. ^ Tighten the servo cover bolts to 12 Nm (9 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 8738 4. Install the new filter neck seal into the transaxle case. A large socket can be used as an installation tool. Two mallets can be used as well. 5. Coat the filter O-ring with a small amount of petroleum jelly, and install the filter into the case. 6. Notice: Push straight down on the center of the oil level control valve in order to prevent damage to the case bore. Install the oil level control valve. 7. Install the oil pan. 8. Lower the vehicle. 9. Remove the AIR. 10. Add DEXRON(r) III P/N 21019223 transaxle fluid or equivalent to the specified refill capacity. ^ The bottom pan removal capacity is approximately 6.5 L (6.9 qt). ^ The complete overhaul capacity is approximately 9 L (9.5 qt). ^ The dry capacity is approximately 12.2 L (12.9 qt). 11. Start the engine, warm up the transaxle, and check for leaks. 12. Inspect the fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 8742 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 8743 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 02-07-30-013E > May > 05 > A/T 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 02-07-30-013E > May > 05 > A/T 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 8752 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 02-07-30-013E > May > 05 > A/T 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 8753 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 8759 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 8760 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 8761 Case: Service and Repair Case Side Cover Replacement Removal Procedure 1. Remove the air cleaner housing assembly. 2. Remove the underhood electrical center from the bracket. 3. Remove the underhood electrical center bracket. 4. Disconnect the shift cable from the PNP switch. 5. Remove the shift cable bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 8762 6. Remove the PNP switch lever nut and lever. 7. Remove the PNP switch. . 8. Remove the transmission upper side cover bolts. 9. Install the engine support fixture. 10. Raise the vehicle. 11. Remove the left front tire and wheel. 12. Remove the left inner fender liner. 13. Remove the wheel drive shaft from the transmission. 14. Remove the power steering gear mounting bolts. 15. Remove the frame. 16. Remove the transmission mount. 17. Lower the vehicle. 18. Lower the engine with the engine support fixture. 19. Raise the vehicle. 20. Remove the transmission side cover lower bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 8763 21. Remove the transmission side cover. Installation Procedure 1. Install the transmission side cover. 2. Notice: Hand start the transmission side cover lower bolts. ^ Tighten the side cover bolts and stud to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. 4. Raise the engine with the engine support fixture. 5. Raise the vehicle. 6. Install the transmission mount. 7. Install the frame. 8. Install the power steering gear mounting bolts. 9. Install the wheel drive shaft to the transmission. 10. Connect the left ball joint to the steering knuckle. 11. Install the left inner fender liner. 12. Install the left front tire and wheel. 13. Lower the vehicle. 14. Remove the engine support fixture. 15. Install the PNP switch. . Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 8764 16. Install the PNP switch lever and nut. ^ Tighten the nut to 35 Nm (26 ft. lbs.). 17. Install the shift cable bracket. 18. Connect the shift cable from the PNP switch. 19. Install the underhood electrical center bracket. 20. Install the underhood electrical center to the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 8765 21. Install the air cleaner housing assembly. 22. Fill the transmission. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 8774 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 8784 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 8798 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 8799 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 8809 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 8810 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever Shifter M/T: All Technical Service Bulletins M/T - Shifter Knob Loose/Detached From Shift Lever Bulletin No.: 05-07-29-006A Date: February 13, 2006 TECHNICAL Subject: Shifter Knob Loose or Detached From Shift Control Lever (Secure Shifter Knob with Adhesive and Fastener) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with 5-Speed Manual Transaxle (RPO MU3) Supercede: This bulletin is being revised to delete the WPC form. Parts are now available from GMSPO and Saturn SPO. Please discard Corporate Bulletin Number 05-07-29-006 (Section 07 Transmission/Transaxle). Condition Some customers may comment that the shift control knob (shifter knob) may be loose or detached from the shift control lever. Cause The interference fit between the shift control knob and the shift control lever may allow the shift control knob to become loose or detached. Correction Secure the original equipment or new service shift control knob to the shift control lever using adhesive and a self-tapping fastener. Service Procedure Important: Make sure the leather boot is still in place around the shift control lever base in order to prevent drilling debris from falling into the shifter mechanism. Important: Re-use the original equipment shifter knob whenever possible. Only use a new service shifter knob if the original equipment knob is damaged or missing. 1. Carefully remove the emblem from the original equipment shift control knob. Save this emblem for re-use if retaining the original equipment shift control knob or for re-use on the new service shift control knob, if applicable. Important: The service shifter knob may feel slightly "looser" than the production part. This is a normal characteristic. Do NOT replace the entire shift control assembly for this condition. 2. Place the shift control knob back on the shift control lever. Ensure that the shifter knob is correctly oriented. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 8820 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 8821 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 8827 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 8828 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 8833 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 8838 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 8839 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 8840 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Capacity Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 6.6L (7.0 Qt) 4T40-E/4T45-E Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 6.5L (6.9 Qt) Overhaul ........................... .............................................................................................................................................................. ................... 9.0L (9.5 Qt) Dry .............................................................................................................. .................................................................................................. 12.2L (12.9 Qt) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 8843 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 8844 Fluid - A/T: Service and Repair TRANSAXLE FLUID CHECKING PROCEDURE NOTE: It is not necessary to check the transmission fluid level. A transmission fluid leak is the only reason for fluid loss. If a leak occurs have it repaired as soon as possible. The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near Room temperature or at 40°C (104°F). CAUTION: Removal of the fluid level screw when the transaxle fluid is hot may cause injury. Use care to avoid contact of transaxle fluid to exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. WARNING: Do not turn the engine off with the fluid level screw removed as you can be injured by hot transaxle fluid being expelled out of the fluid check hole. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. 6. Place oil container under fluid level screw. 7. Remove the fluid level screw with the engine running at idle. 8. Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID. 9. Install fluid level screw. Tighten 12 Nm (106 lb. in.) 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid: With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten 12 Nm (106 lb. in.) 2. Lower vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement ^ Tools Required: J 6125-1B Slide Hammer - J 23129 Axle Boot Remover Removal Procedure 1. Raise and support the vehicle. Caution: Refer to Vehicle Lifting Caution in Service Precautions. 2. Place the drain pan under the transaxle oil pan. 3. Remove the oil pan bolts from only the front and the sides. Notice: When removing the oil pan bolts, be careful not to damage the oil pan sealing surfaces. Such damage may result in oil leaks in this area. 4. Loosen the rear oil pan bolts about 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the fluid to drain. 6. Inspect the fluid color. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 8848 9. Remove the oil pan gasket. 10. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 11. Check the oil filter seal for damage or wear. 12. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of J 36850 or petroleum jelly. 2. Install a new filter into the case. 3. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged. 4. Clean and dry the oil pan. Inspect the pan for damage and replace the pan if necessary. 5. Install the oil pan. 6. Clean and dry the oil pan. Inspect the pan for damage and replace the pan if necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 8849 7. Install the oil pan. 8. Notice: Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 9. Lower the vehicle. 10. Fill the transaxle to the proper level with DEXRON(r) III fluid or the equivalent. 11. Inspect the pan for leaks. Recheck the transmission fluid level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 8854 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Pipes Replacement Fluid Line/Hose: Service and Repair Automatic Transmission Oil Cooler Pipes Replacement Automatic Transmission Oil Cooler Pipes Replacement Removal Procedure 1. Raise and support the vehicle. Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 2. Position a drain pan under the transaxle cooler pipes. 3. Remove the transaxle oil cooler pipes retaining nut from the transaxle. 4. Remove the transaxle oil cooler pipes from the transaxle. 5. Using J 41623-B remove the transaxle oil cooler pipes from the fittings at the radiator. 6. Remove the transaxle oil cooler pipe from the retaining clip at the radiator. 7. Remove the transaxle oil cooler pipes from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Pipes Replacement > Page 8857 1. Install the transaxle oil cooler pipes to the vehicle. 2. Install the transaxle oil cooler pipes to the fittings at the radiator. 3. Install the transaxle oil cooler pipe to the retaining clip at the radiator. 4. Install the transaxle oil cooler pipes to the transaxle. 5. Notice: Install the transaxle oil cooler pipe retaining nut. ^ Tighten the nut to 7 Nm (62 inch lbs.). 6. Remove the drain pan. 7. Lower the vehicle. 8. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. Adjust the transmission fluid level. 9. Inspect for fluid leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Pipes Replacement > Page 8858 Fluid Line/Hose: Service and Repair Oil Feed Pipes Replacement Oil Feed Pipes Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise the vehicle. Support the vehicle. 3. Remove the transmission oil pan. 4. Remove the transmission oil filter assembly. 5. Remove the oil feed pipe bolts. 6. Inspect the eight oil feed pipe seal rings. 7. Replace the seal rings only if the seal rings are cut, swollen or damaged. 8. Remove the low/reverse band oil pipe assembly. 9. Remove the eight low/reverse band oil pipe assembly seals. 10. Inspect the oil feed pipes for plugged passages, bent pipes, or cracks. 11. Inspect the oil feed pipe seal rings. Verify the proper location of the seal rings. Replace the seal rings if these are cut, swelled or damaged. Installation Procedure 1. Install the eight low/reverse band oil pipe assembly seals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Pipes Replacement > Page 8859 2. Install the low/reverse band oil feed pipe assembly onto the transmission. 3. Notice: Hand start the bolts that attach the oil feed pipe assembly to the transmission. ^ Tighten the bolts to 14 Nm (124 inch lbs.). 4. Install the transmission oil filter assembly. 5. Install the transmission oil pan and gasket. 6. Lower the vehicle. 7. Refill the transmission to the proper level. 8. Inspect the transmission oil level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil Pan ^ Tighten the bolts to .............................................................................................................................. ...................................... 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 8863 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise and support the vehicle. 2. Loosen the oil pan bolts. 3. Drain the oil. Use a suitable container to catch the transmission fluid. 4. Remove the oil pan attaching bolts. 5. Remove the oil pan. 6. Remove the oil pan gasket. Installation Procedure 1. Clean and inspect the oil pan for dents or damage. Dry the oil pan before installation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 8864 2. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged. 3. Install the oil pan. Replace the bottom pan if damaged. 4. Notice: Install the oil pan attaching bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 5. Lower the vehicle. 6. Check the pan for leaks. Refill the transmission to the proper level with DEXRON(r)-III. 7. Recheck the fluid level. 8. Inspect the oil pan gasket for leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8868 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8869 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Technical Service Bulletins > A/T - 4T65-E Final Drive Assembly Precaution Output Shaft Bearing/Bushing: Technical Service Bulletins A/T - 4T65-E Final Drive Assembly Precaution Bulletin No.: 04-07-30-030 Date: July 02, 2004 INFORMATION Subject: Using Caution When Servicing Final Drive Unit on 4T65-E Transaxles To Insure Internal Gear Thrust Bearing (695) is Properly Seated/Located Models: 2001-2005 GM Passenger Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) When servicing a final drive unit on a 4T65-E transaxle, use extreme caution to ensure that the internal gear thrust bearing (695) is properly seated/located. It has been found that after servicing a final drive unit on 4T65-E transaxles, the internal gear thrust bearing (695) was not properly seated/located causing internal damage and a repeat repair. Use a generous amount of Transgel J 36850 when installing the internal gear thrust bearing (695) to the park gear (696) to ensure the internal thrust bearing (695) will retain its proper position during assembly. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8885 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8886 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 8892 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 8901 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 8907 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8913 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8914 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8915 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 8916 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 8917 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 8918 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement Seals and Gaskets: Service and Repair Case Side Cover Seal Replacement Case Side Cover Seal Replacement ^ Tools Required J 41227 Output Shaft Sleeve Remover - J 41228 Output Shaft Seal Installer - J 41102 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Caution: Refer to Vehicle Lifting Caution in Service Precautions. 2. Remove the drive axle assembly. 3. Use a medium screwdriver and a mallet in order to remove the case cover seal. 4. Remove the drive axle retaining clip from the output axle. 5. Use the J 41227 in order to remove the sleeve from the output axle shaft. 6. Clean and inspect the seal bore. 7. Use fine sand paper in order to remove any burrs or nicks. Clean the entire area after any sanding. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement > Page 8921 Installation Procedure 1. Use the J 41102 and a mallet in order to install the new case cover seal. 2. Use the J 41228 in order to install a new sleeve on the output axle. Install the J 41228 so that the collar is in the snap ring groove. 3. Install the axle shaft retaining clip onto the output axle. 4. Install the drive axle assembly. 5. Lower the vehicle. 6. Inspect the shaft sleeve for leaks. 7. Inspect the transmission oil level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement > Page 8922 Seals and Gaskets: Service and Repair Stub Axle Shaft Sleeve and Seal Replacement Stub Axle Shaft Sleeve and Seal Replacement ^ Tools Required J 38868 Shaft Removal Tool - J 6125-1B Slide Hammer - J 23129 Universal Seal Remover - J 41102 Axle Seal Installer Removal Procedure 1. Raise and support the vehicle. Important: Do not damage the seal bore or the sleeve assembly. Fluid leaks may result. 2. Remove the drive axle assembly. 3. Remove the snap ring from the stub axle shaft. Discard the snap ring. Do not reuse. 4. Remove the stub shaft from the transmission. Use the J 6125-1B and the J 38868. 5. Pull lightly on the shaft. Rotate the shaft until the stub shaft snap ring at the differential seats in the taper on the differential side gear. 6. Remove inner snap ring. 7. Remove the right hand axle seal from the transmission. Use the J 23129 and the J 6125-1B. Installation Procedure Important: The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. 1. Install the new seal. Use the J 41102. Lubricate the seal lip with a light wipe of transmission oil. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement > Page 8923 2. Important: Carefully guide the axle shaft past the lip seal. Do not allow the shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. Install the two new snap rings on the stub shaft. 3. Install the stub shaft into the transmission. Use a mallet. 4. Install the drive axle assembly. 5. Lower the vehicle. 6. Inspect the oil level. 7. Inspect the shaft and the seal for leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement > Page 8924 Seals and Gaskets: Service and Repair Output Axle Shaft Sleeve and Seal Replacement Output Axle Shaft Sleeve and Seal Replacement ^ Tools Required J 41227Output Shaft Sleeve Remover - J 41228 Output Shaft Sleeve Installer Removal Procedure 1. Raise the vehicle. Support the vehicle. 2. Remove the drive axle assembly. 3. Remove the snap ring from axle. 4. Remove the output axle seal. 5. Use the J 41227 to remove the sleeve from the output axle. Installation Procedure Important: The output axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Case Side Cover Seal Replacement > Page 8925 1. Use the J 41228 to install a new sleeve on the output axle shaft. Ensure that the collet is located in the snap ring groove when installing. 2. Install the new output axle seal. 3. Install one new snap ring on the output shaft. 4. Install the drive axle assembly. 5. Lower the vehicle. 6. Inspect the output axle shaft sleeve for leaks. 7. Inspect the oil level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Page 8930 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Page 8931 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8935 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 8936 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8945 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8946 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8947 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8953 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8954 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8955 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8959 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8960 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8961 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8962 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 8963 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8967 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8983 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8984 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8985 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8991 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8992 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 8993 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 8997 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 8998 Shift Solenoid: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 8999 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 9002 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shifter A/T: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9011 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9012 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9013 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Shifter A/T: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 9018 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 05-07-30-015 > Jun > 05 > A/T 4T45E Hard to Shift Into Gear Shifter A/T: Customer Interest A/T - 4T45E Hard to Shift Into Gear Bulletin No.: 05-07-30-015 Date: June 02, 2005 TECHNICAL Subject: Hard To Shift Or Select Vehicle Gear, Shifter Sticks/Binds/Jams (Replace Shifter Control Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada) with 4T45E Automatic Transaxle (MN5) Condition Some customers may comment that the button on the shifter handle is stuck and will not move. Correction Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. If the park pawl pin does move, refer to normal diagnostics in SI. 1. Set the parking brake. 2. Shift the vehicle into NEUTRAL. 3. Turn and slide down the shift control sleeve (3). 4. Loosen the shift control handle screw (2) with an allen wrench. 5. Remove the shift control handle (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 05-07-30-015 > Jun > 05 > A/T 4T45E Hard to Shift Into Gear > Page 9023 6. Install the new shift control handle (1) (refer to Parts Information below). Tighten Tighten the shift control handle screw (2) to 10 N.m (88 lb in). 7. Reinstall the shift control sleeve (3) by sliding the sleeve up into place. Ensure that it is locked into place. 8. Test the shift control operation. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shifter A/T: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9029 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9030 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9031 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Shifter A/T: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 9036 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 05-07-30-015 > Jun > 05 > A/T - 4T45E Hard to Shift Into Gear Shifter A/T: All Technical Service Bulletins A/T - 4T45E Hard to Shift Into Gear Bulletin No.: 05-07-30-015 Date: June 02, 2005 TECHNICAL Subject: Hard To Shift Or Select Vehicle Gear, Shifter Sticks/Binds/Jams (Replace Shifter Control Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada) with 4T45E Automatic Transaxle (MN5) Condition Some customers may comment that the button on the shifter handle is stuck and will not move. Correction Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. If the park pawl pin does move, refer to normal diagnostics in SI. 1. Set the parking brake. 2. Shift the vehicle into NEUTRAL. 3. Turn and slide down the shift control sleeve (3). 4. Loosen the shift control handle screw (2) with an allen wrench. 5. Remove the shift control handle (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 05-07-30-015 > Jun > 05 > A/T - 4T45E Hard to Shift Into Gear > Page 9041 6. Install the new shift control handle (1) (refer to Parts Information below). Tighten Tighten the shift control handle screw (2) to 10 N.m (88 lb in). 7. Reinstall the shift control sleeve (3) by sliding the sleeve up into place. Ensure that it is locked into place. 8. Test the shift control operation. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Page 9042 Shifter A/T: Service and Repair Shift Control Replacement Removal Procedure 1. Remove the console. 2. Disconnect the shift cable from the shift control assembly. 3. Remove the shift control nuts. 4. Disconnect the shift lock solenoid harness connector. 5. Remove the shift control from the vehicle. Installation Procedure 1. Install the shift control to the vehicle. 2. Connect the shift lock solenoid harness connector. 3. Notice: Install the shift control nuts. ^ Tighten the shift control nuts to 25 Nm (18 ft. lbs.). 4. Connect the shift cable to the shift control assembly. 5. Install the console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair Shift Cable: Service and Repair Shift Control Cable Replacement - Floor Shift Removal Procedure 1. Raise and support the vehicle. 2. Remove the shift cable retaining nut near the exhaust heat shield. 3. Remove the shift cable from the transmission cable bracket. 4. Disconnect the shift cable from the park/neutral position switch. 5. Lower the vehicle. 6. Remove the console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 9047 7. Disconnect the shift cable from the shift control assembly. 8. Position the driver's side front carpet aside. 9. Separate the grommet from the floor pan. 10. Remove the cable from the vehicle by pulling the cable through the driver's floor opening. Installation Procedure 1. Insert the cable through the driver's floor opening. 2. Install the grommet flush with the floor opening. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 9048 3. Install the driver's side front carpet. 4. Connect the shift cable to the shift control assembly. 5. Install the console. 6. Raise the vehicle. 7. Connect the shift cable to the park/neutral position switch. 8. Connect the shift cable to the transmission cable bracket. 9. Notice: Install the shift cable retaining nut near the exhaust heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 9049 ^ Tighten the nut to 10 Nm (89 inch lbs.). 10. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9058 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9059 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9065 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9066 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 9071 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 9072 Torque Converter: Service and Repair Torque Converter, Turbine Shaft Seal Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the transmission assembly from the vehicle. 3. Remove the torque convertor assembly from the transmission. 4. Remove the torque convertor O-ring seal from the end of the turbine shaft. Use a screwdriver. Installation Procedure 1. Install a new torque convertor O-ring seal on the end of the turbine shaft. 2. Install the torque convertor onto the transmission. 3. Install the transmission into the vehicle. 4. Connect the negative battery cable. 5. Adjust the transmission oil level. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 9077 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 9081 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 9082 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9087 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9088 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9089 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 9090 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Testing and Inspection Transmission Mount: Testing and Inspection Transmission Mount Inspection Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise and support the vehicle. 2. Place a jack stand under the transmission/transaxle. 3. Place a block of wood between the jack stand and the transaxle in order to protect the transmission/transaxle pan. 4. Important: Before replacing any transmission/transaxle mount due to suspected fluid loss, verify that the source of the fluid is the transmission/transaxle mount, not the engine, transmission/transaxle or accessories. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 5. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: ^ The hard rubber surface is covered with heat check cracks. ^ The rubber is separated from the metal plate of the transmission/transaxle mount. ^ The rubber is split through the center of the transmission/transaxle mount. 6. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. 7. Remove the Jack stand and block of wood from under the vehicle. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front Transmission Mount: Service and Repair Transmission Mount Replacement - Front Transmission Mount Replacement - Front Removal Procedure 1. Raise and support the vehicle. 2. Remove the front transaxle mount thru bolt. 3. Remove the front transaxle mount to transaxle bolts. 4. Remove the front transaxle mount from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9096 1. Important: The transaxle bolts must be torqued in a mandatory sequence as shown. Notice: Install the front transaxle mount and transaxle bolts. ^ Tighten the bolts to 90 Nm (66 ft. lbs.). 2. Hand tighten the front transaxle mount thru bolt. 3. Important: The front and rear transmission mounts must be allowed to settle with the thru bolts loosened. Loosen the rear transmount thru bolt. 4. Tighten the transmission mount thru bolts in the following order. 1. Tighten the rear bolt to 100 Nm (74 ft. lbs.). 2. Tighten the front bolt to 100 Nm (74 ft. lbs.). 5. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9097 Transmission Mount: Service and Repair Transmission Mount Replacement - Rear Transmission Mount Replacement - Rear Removal Procedure 1. Raise and support the vehicle. 2. Remove the rear transaxle mount thru bolt and heat shield. 3. Remove the rear transaxle mount to frame bolts. 4. Remove the rear transaxle mount. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9098 1. Install the rear transaxle mount to frame bolts. Hand tighten the bolts. 2. Install the rear transaxle mount, heat shield and the thru bolt to the transmission bracket. Hand tighten the bolt. 3. Notice: Tighten the rear transaxle mount to frame bolts. ^ Tighten the bolts to 60 Nm (44 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9099 4. Important: Rotate the rear transaxle mount heat shield clockwise until the tab is seated on the mount bracket. Important: The front and rear transmission mounts must be allowed to settle with the thru bolts loosened. Loosen the front transaxle mount thru bolt but do not remove the bolt. 5. Tighten the rear transmission mount thru bolt. ^ Tighten the thru bolt to 100 Nm (74 ft. lbs.). 6. Tighten the front transmission mount thru bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9100 ^ Tighten the thru bolt to 100 Nm (74 ft. lbs.). 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9101 Transmission Mount: Service and Repair Transmission Mount Replacement - Side Transmission Mount Replacement - Side Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the front transmission mount thru bolt. 4. Remove the rear transmission mount thru bolt. 5. Lower the vehicle. 6. Remove the under hood electrical center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9102 7. Disconnect the engine control module harness connector (3,4). 8. Disconnect the positive battery cables (1) from the under hood electrical center. 9. Disconnect the surge tank inlet hose from the surge tank. 10. Remove the under hood electrical center tray bracket nuts (1,2) and bolt (3). 11. Disconnect the wiring harness retainer from the tray bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9103 12. Lift the electrical center up and swing it back and out of the way. 13. Support the transmission with an hydraulic floor jack. Use a block of wood between the jack and the transmission. 14. Remove the transmission mount to transmission bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9104 15. Remove the transmission mount to mid-rail bolts. 16. Using the floor jack, slowly lower the transmission just enough to remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the mid-rail. 2. Notice: Hand start the transmission mount to mid-rail bolts. ^ Tighten the bolts to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9105 3. Using a hydraulic jack, raise the transmission until it contacts the transmission mount. 4. Important: The transmission mount to transmission bolts must be hand started. Do not pry the transmission or mount to align the holes. Hand start the transmission mount to transmission bolts using the following sequence: 1. Rear Bolt 2. Middle Bolt 3. Front Bolt 5. Using the previous sequence, tighten the transmission mount bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 6. Reposition the under hood electrical center. 7. Connect the wiring harness retainer to the tray bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9106 8. Install the electrical center nuts (1,2) and bolts (3). ^ Tighten the nut to 10 Nm (89 inch lbs.). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 9. Connect the surge tank inlet hose to the surge tank. 10. Install the positive battery cables (1) to the under hood electrical center. ^ Tighten the positive cable nut to 15 Nm (11 ft. lbs.). 11. Connect the engine control module harness connectors (3,4). 12. Install the under hood electrical center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Replacement - Front > Page 9107 13. Raise the vehicle. 14. Hand tighten the front transmission mount thru bolt 15. Hand tighten the rear transmission mount thru bolt. 16. ^ Tighten the front transmission mount thru bolt. ^ Tighten the bolt to 100 Nm (74 ft. lbs.). 17. ^ Tighten the rear transmission mount thru bolt. ^ Tighten the bolt to 100 Nm (74 ft. lbs.). 18. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9111 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9112 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9113 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9114 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9115 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9119 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: Customer Interest A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9131 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9132 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9133 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9134 Left Side Control Valve Body Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9135 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9136 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 9141 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 9142 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: All Technical Service Bulletins A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9152 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9153 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9154 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9155 Left Side Control Valve Body Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9156 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 9157 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 9162 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 9163 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 9169 Valve Body: Diagrams Disassembled Views Control Valve Body Assembly Control Valve Body Assembly 300 - Control Valve Body Assembly 300 - Control Valve Body Assembly 301 - 1-2 Shift Valve Spring 302 - 1-2 Shift Valve 303 - Shift Solenoid O-Ring (1-2 and 2-3) 303 - Shift Solenoid O-Ring (1-2 and 2-3) 304 - Retainer Clip 304 - Retainer Clip Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 9170 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 304 - Retainer Clip 305 - Shift Solenoid (1-2 and 2-3) 305 Shift Solenoid (1-2 and 2-3) 306 - 2-3 Shift Valve Spring 307 - 2-3 Shift Valve 308 - Torque Signal Regulator Valve Spring 309 - Torque Signal Regulator Valve 310 - Pressure Control Solenoid O-Ring 311 - Pressure Control Solenoid O-Ring 312 - Pressure Control Solenoid 313 - Actuator Oil Filter O-Ring 314 - Actuator Oil Filter 315 - Actuator Feed Limit Valve 316 - Actuator Feed Limit Valve Spring 317 - Bore Plug 318 - 3-4 Shift Valve Spring 319 - 3-4 Shift Valve 320 - 3-4 Shift Valve Plug O-Ring 321 - Bore Plug 323 - 1-2/3-4 Accumulator Valve 324 - Pressure Regulator Boost Valve Bushing 325 - Pressure Regulator Boost Valve 326 - Isolator Spring 327 - Pressure Regulator Valve Spring 328 - Pressure Regulator Valve 333 - TCC Control Valve Spring 334 - TCC Control Valve 335 - TCC Control PWM Solenoid 337 - TCC Control Solenoid O-Ring 338 - TCC Control Solenoid O-Ring 339 - TCC Regulated Apply Valve 340 - TCC Regulated Apply Valve Spring 341 - Bore Plug Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 9171 Valve Body: Service and Repair Control Valve Body Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the bolts (9, 12 and 16) from the control valve body assembly (18). 3. Remove the control valve body assembly (18). 4. Remove and discard the valve body to spacer plate gasket (22). Installation Procedure 1. Install the control valve body to spacer plate gasket (22) onto the spacer plate (23). 2. Install the control valve body assembly (18) onto the gasket (22). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 9172 3. Inspect the TFP switch assembly (13) in order to verify the condition and correct location of the seven pressure switch O-rings. 4. If necessary replace the pressure switch O-rings. 5. Install the TFP switch assembly (13) onto the control valve body assembly. 6. Install the eighteen control valve body assembly bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 9173 7. Notice: Hand start the bolts. ^ Tighten the bolts to 14 Nm (124 inch lbs.). 8. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair Wiring Harness: Service and Repair Wiring Harness Replacement Removal Procedure ^ Tools Required J 41101 Pass-Through Connector Remover 1. Remove the transmission side cover. 2. Remove the control valve body. 3. Push the J 41101 onto the pass-through connector from the outside of the transmission case in order to compress the pass-through connector's retaining tabs. 4. With the retaining tabs compressed, use a screwdriver in order to remove the pass-through connector through the inside of the transmission case. 5. Remove the wiring harness (11). Installation Procedure Connect the wiring harness assembly to the following components: ^ The TFP switch assembly (13) ^ The pressure control solenoid (312) (red connector) Important: The 1-2 shift solenoids wires are red and light green. The 2-3 shift solenoid wires are red and yellow. ^ The 1-2 shift solenoid (305) (white connector) ^ The 2-3 shift solenoids (305) (white connectors) ^ The TCC solenoid (335) ^ Install the control valve body. ^ Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 9183 Clutch Fluid: Fluid Type Specifications HYDRAULIC CLUTCH FLUID Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > M86 Clutch Master Cylinder: Service and Repair M86 Clutch Master Cylinder Replacement (M86) Removal Procedure 1. Remove the clutch pedal retainer from the front of the clutch pedal assembly. 2. Pull the clutch pedal upward in order to disengage the clutch master cylinder pushrod from the clutch pedal. 3. Remove the UBEC. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 4. Place a shop towel under the clutch master cylinder in order to catch any fluid loss. 5. Disconnect the clutch hose (1) from the clutch master cylinder. 6. Disconnect the clutch line (2) from the clutch master cylinder. 7. Cap the reservoir and hydraulic lines in order to prevent fluid loss and contamination. 8. Rotate the clutch master cylinder one 1/4 turn clockwise and remove the cylinder from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > M86 > Page 9188 Important: While installing, ensure that the clutch master cylinder pushrod is aligned with he clutch pedal. 1. Install the clutch master cylinder while rotating 1/4 turn counterclockwise. 2. Uncap the reservoir and hydraulic lines. 3. Connect the clutch line (2) to the clutch master cylinder. 4. Connect the clutch hose (1) to the clutch master cylinder. 5. Install the UBEC. 6. Connect the clutch master cylinder pushrod to the clutch pedal. 7. Install the clutch pedal retainer. 8. Bleed the clutch hydraulic system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > M86 > Page 9189 Clutch Master Cylinder: Service and Repair MU3 Clutch Master Cylinder Replacement (MU3) Removal Procedure 1. Remove the clutch pedal retainer from the front of the clutch pedal assembly. 2. Pull the clutch pedal upward in order to disengage the clutch master cylinder pushrod from the clutch pedal. 3. Remove the UBEC. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 4. Place a shop towel under the clutch master cylinder in order to catch any fluid loss. 5. Disconnect the clutch hose (1) from the clutch master cylinder. 6. Disconnect the clutch line (2) from the clutch master cylinder. 7. Cap the reservoir and hydraulic lines in order to prevent fluid loss and contamination. 8. Rotate the clutch master cylinder one 1/4 turn clockwise and remove the cylinder from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > M86 > Page 9190 Important: While installing, ensure that the clutch master cylinder pushrod is aligned with he clutch pedal. 1. Install the clutch master cylinder while rotating 1/4 turn counterclockwise. 2. Uncap the reservoir and hydraulic lines. 3. Connect the clutch line (2) to the clutch master cylinder. 4. Connect the clutch hose (1) to the clutch master cylinder. 5. Install the UBEC. 6. Connect the clutch master cylinder pushrod to the clutch pedal. 7. Install the clutch pedal retainer. 8. Bleed the clutch hydraulic system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement Removal Procedure 1. Disconnect the clutch actuator cylinder line. 2. Remove the transmission. 3. Remove the clutch actuator cylinder bolts from the transmission. 4. Remove the following components from the transmission: ^ The upper bolt ^ The clutch actuator cylinder Installation Procedure Important: Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder. 1. Lubricate the inside diameter of the bearing with Saturn P/N 21005995, or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 9194 2. Install the clutch actuator cylinder to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the clutch actuator cylinder bolts ^ Tighten the bolts to 10 Nm (89 inch lbs.). 4. Install the upper line release bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 5. Install the transmission. 6. Connect the clutch actuator cylinder line. 7. Bleed the hydraulic system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > M86 Hydraulic Hose: Service and Repair M86 Hydraulic Clutch Hose/Pipe Replacement (M86) Removal Procedure 1. Remove the UBEC. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 2. Place a shop towel under the clutch master cylinder and brake master cylinder reservoir in order to catch any additional fluid loss. 3. Disconnect the clutch hose (1) from the clutch master cylinder and brake master cylinder reservoir. 4. Disconnect the clutch line (2) at the clutch actuator cylinder and the transaxle and drain the fluid into a suitable container. Installation Procedure Important: Ensure that the clutch line locks securely in place. 1. Connect the clutch line (2) to the clutch master cylinder and the transaxle. 2. Connect the clutch hose (1) to the clutch actuator cylinder and the brake master cylinder reservoir. 3. Remove the shop towel and discard in a suitable container. 4. Install the UBEC. 5. Fill the brake/clutch reservoir with DOT 3 hydraulic fluid to the proper fluid level. 6. Bleed the clutch hydraulic system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > M86 > Page 9199 Hydraulic Hose: Service and Repair MU3 Hydraulic Clutch Hose/Pipe Replacement (MU3) Removal Procedure 1. Remove the UBEC. 2. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Place a shop towel under the clutch master cylinder and brake master cylinder reservoir in order to catch any additional fluid loss. 3. Disconnect the clutch hose (1) from the clutch master cylinder and brake master cylinder reservoir. 4. Disconnect the clutch line (2) at the clutch actuator cylinder and the transaxle and drain the fluid into a suitable container. Installation Procedure 1. Important: Ensure that the clutch line locks securely in place. Connect the clutch line (2) to the clutch master cylinder and the transaxle. 2. Connect the clutch hose (1) to the clutch actuator cylinder and the brake master cylinder reservoir. 3. Remove the shop towel and discard in a suitable container. 4. Install the UBEC. 5. Fill the brake/clutch reservoir with DOT 3 hydraulic fluid to the proper fluid level. 6. Bleed the clutch hydraulic system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations Clutch Pedal Assembly: Locations Manual Transmission Component Views Pedal Components Pedal Components 1 - Clutch Pedal Position (CCP) Switch (M86) 2 - Clutch Start Switch (M86) 3 - Stop Lamp Switch 4 - Cruise Control Cancel Switch (M86) 5 - Accelerator Pedal Position (APP) Sensor 6 - Floor Pan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations > Page 9203 Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Remove the clutch pedal pivot nut. 2. Disconnect the clutch start switch (2) from the clutch pedal bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations > Page 9204 3. Depress the tabs of the clutch master cylinder pushrod retainer and release the clutch pedal from the pushrod. 4. Remove the clutch pedal bracket to front of dash nuts. 5. Lower the clutch pedal assembly slightly and disconnect the electrical connector from the clutch pedal position (CPP) switch, then remove the assembly. Installation Procedure 1. Connect the electrical connector to the CPP switch and install the clutch pedal assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch pedal bracket to front of dash nuts. ^ Tighten the nuts to 10 Nm (89 inch lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations > Page 9205 3. Install the clutch master cylinder pushrod to the clutch pedal, ensure that the pushrod retainer is fully seated to the pedal. 4. Install the clutch pedal pivot nut. ^ Tighten the nut to 10 Nm (89 inch lbs.). 5. Connect the clutch start switch (2) to the clutch pedal bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations > Page 9206 6. If a new clutch pedal assembly was installed, perform the following steps to adjust the pedal position switch: 1. Insert the position switch (2) through the switch retainer on the clutch pedal bracket. 2. While holding the pedal in the fully released position, press the switch (2) toward the pedal until the barrel of the switch touches the shipping clip (1) on the new pedal assembly. 3. Rotate the switch (2) clockwise to secure. 4. Remove the shipping clip (1) from the new pedal assembly. 7. Adjust the clutch start switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 9215 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition > Page 9221 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Technical Service Bulletins > Page 9222 Clutch Switch: Locations Manual Transmission Component Views Pedal Components Pedal Components 1 - Clutch Pedal Position (CCP) Switch (M86) 2 - Clutch Start Switch (M86) 3 - Stop Lamp Switch 4 - Cruise Control Cancel Switch (M86) 5 - Accelerator Pedal Position (APP) Sensor 6 - Floor Pan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > M86 Clutch Switch: Diagrams M86 Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > M86 > Page 9225 Clutch Start Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > M86 > Page 9226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Adjustments > Old Pedal Clutch Switch: Adjustments Old Pedal Clutch Pedal Position Switch Adjustment (Old Pedal) Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Remove the CPP switch (1) from the clutch pedal by twisting the CPP switch (1) counterclockwise. Installation Procedure 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly and twist the CPP switch (1) clockwise to seat. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Remove the drill bit. 5. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Adjustments > Old Pedal > Page 9229 Clutch Switch: Adjustments New Pedal Clutch Pedal Position Switch Adjustment (New Pedal) Installation Procedure 1. While holding the pedal in the fully released position, press the switch (2) toward the pedal until the barrel of the switch (2) touches the shipping clip (1). 2. Remove the shipping clip (1). 3. Connect the electrical connector (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Adjustments > Page 9230 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Rotate the CPP switch (1) counterclockwise to release, and remove the switch from the clutch pedal assembly. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Adjustments > Page 9231 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Rotate the switch (1) clockwise to secure. 5. Remove the drill bit. 6. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > M86 Pressure Plate: Specifications M86 Clutch cover ^ Follow the tightening sequence. Tighten the bolts to ........................................................................ ............................................................................................... 24 Nm (18 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > M86 > Page 9236 Pressure Plate: Specifications MU3 Clutch cover to flywheel bolts in the sequence shown. ^ Tighten the bolts to ........................................................................................................................... ...................................... 30 Nm (22 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > M86 Pressure Plate: Service and Repair M86 Clutch Drive Plate and Clutch Driven Plate (M86) ^ Tools Required J 43482 Clutch Alignment Arbor Removal Procedure 1. Remove the transmission. 2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. 3. Remove the clutch cover and the clutch disc. Installation Procedure 1. Align the Heavy Side of the flywheel assembly , with the clutch cover Light Side. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > M86 > Page 9239 2. Install the J 43482 in order to support the clutch cover to the flywheel assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the clutch cover to flywheel bolts. ^ Follow the tightening sequence. Tighten the bolts to 24 Nm (18 ft. lbs.). 4. Remove the J 43482. Important: Excessive amounts of lubricant on the input shaft splines may contaminate the clutch disc and cause clutch shudder. 5. Lubricate the inside diameter of the bearing with Saturn P/N 21005995, or equivalent. 6. Install the transmission. 7. Bleed the hydraulic system. 8. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > M86 > Page 9240 Pressure Plate: Service and Repair MU3 Clutch Drive Plate and Clutch Driven Plate (MU3) ^ Tools Required J 43482 Clutch Alignment Arbor Removal Procedure 1. Remove the transmission. 2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. 3. Remove the clutch cover and the clutch disc. Installation Procedure 1. Install the clutch disc and the clutch cover. 2. Hand start the clutch cover to flywheel bolts, leaving the clutch cover loose enough to reposition for alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > M86 > Page 9241 3. Install the J 43482 in order to support the clutch cover to the flywheel assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. ^ Tighten the clutch cover to flywheel bolts in the sequence shown. ^ Tighten the bolts to 30 Nm (22 ft. lbs.). 5. Recheck each bolt torque using the tightening sequence. 6. Remove the J 43482. Important: Excessive amounts of lubricant on the input shaft splines may contaminate the clutch disc and cause clutch shudder. 7. Lubricate the inside diameter of the bearing with Saturn P/N 21005995, or equivalent. 8. Install the transmission. 9. Bleed the hydraulic system. 10. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Seal Replacement GKN Wheel Drive Shaft Inner Joint and Seal Replacement (GKN) ^ Tools Required J 8059 Snap Ring Pliers (Parallel Jaw) - J 35910 Drive Axle Seal Clamp Pliers - J 41048 Drive Axle Swage Ring Clamp Removal Procedure 1. Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. Disconnect the swage ring from the shaft using a hand grinder to cut through the ring, taking care not to damage the shaft. 2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp. 3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along the shaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9253 5. Remove the housing (1) from the tripot joint spider and the shaft (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9254 6. Remove the spacer ring (1), spider assembly (2), spacer ring (3) using J 8059, and tripot boot (4). Discard the boot and rings. 7. Clean the shaft (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 8. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Installation Procedure 1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small swage ring (2) onto the shaft. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the shaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9255 3. Mount J 41048 in a vise and proceed as follows: 1. Position the inboard end (1) of the wheel drive shaft assembly in tool J 41048. 2. Align the top of seal neck on the bottom die using the indicator. 3. Place the top half of the J 41048 on the lower half. 4. Before proceeding, ensure there are no pinch points on the wheel drive shaft inboard seal. This could cause damage to the inboard seal. 5. Insert the bolts (2). 6. Tighten the bolts by hand until snug. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9256 4. Notice: Refer to Fastener Notice in Service Precautions. Align the following items: ^ The inboard seal (1) ^ The shaft ^ The swage ring (2) Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9257 5. Install the spacer ring (2) into the groove of the shaft using J 8059. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9258 6. Slide the tripot joint spider assembly (4) toward the spacer ring (1) as far as it will go on the shaft. 7. Install the spacer ring (2) into the groove of the shaft J 8059. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9259 8. Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing. 9. Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). Install the new trilobal tripot bushing (3) to housing (1). 10. Position the larger new seal retaining clamp (2) on the inboard seal. 11. Slide the housing (1) over the tripot joint spider assembly on the shaft. 12. Slide the large diameter of the inboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. 13. Important: The inboard seal must not be dimpled, stretched out or out of shape in any way. If the inboard seal is not shaped correctly, carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Shape Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9260 the inboard seal properly by hand. Remove the tool. Position the joint assembly at the proper vehicle dimension: 95 mm (3.75 inch). 14. Align the following items while latching: ^ The inboard seal ^ The tripot housing (2) ^ The large seal retaining clamp (3) Crimp the seal retaining clamp with J 35910 to 176 Nm (130 ft. lbs.). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary. 15. Check the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension of 2.60 mm (0.102 inch) is reached. 16. Fully stroke the joint several times to disperse the grease. Delphi Wheel Drive Shaft Inner Joint and Seal Replacement (Delphi) ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Drive Axle Seal Clamp Pliers - DT-47732 Drive Axle Swage Ring Clamp Disassembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9261 1. Important: With removal of the wheel driveshaft for any reason, the transmission sealing surface (the tripot male/female shank of the wheel driveshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotation motion. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the wheel driveshaft reinstalled free of any buildup. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1). 2. Remove the large boot retaining clamp from the tripot joint with side cutter. 3. Dispose of the large boot retaining clamp. 4. Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. Separate the wheel driveshaft inboard boot from the trilobal tripot bushing (3) at the large diameter. 5. Slide the boot (4) away from the joint along the shaft. 6. Remove the housing (1) from the tripot joint spider (2) and the shaft. 7. Remove and discard the trilobal tripot bushing (3) from the housing (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9262 8. Remove and discard the lower spacer ring (1) from the groove (5) on the shaft. 9. Slide tripot joint spider assembly (2) off of the shaft. 10. Remove and discard the second spacer ring (3) from the shaft. 11. Clean the following items with cleaning solvent: ^ The tripot balls ^ The needle rollers ^ The housing 12. Remove all traces of old grease and any contaminates. Dry all parts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9263 13. Inspect the following parts for damage or wear: ^ The tripot joint spider assembly (2) ^ The housing (1) ^ The needle rollers Assembly Procedure 1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the small boot clamp (2) onto the shaft. 2. Position the small end of the joint boot (1) into the joint boot groove (3) on the shaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9264 3. Mount DT-47732 in a vise and proceed as follows: 1. Position the inboard end (1) of the wheel driveshaft assembly in tool DT-47732. 2. Align the top of boot neck on the bottom die using the indicator. 3. Place the top half of tool DT-47732 on the lower half of tool. 4. Before proceeding, ensure there are no pinch points on the wheel driveshaft inboard boot. This could cause damage to the inboard boot. 5. Insert the bolts (2). 6. Tighten the bolts by hand until snug. 4. Notice: Refer to Fastener Notice in Service Precautions. Align the following items: ^ The inboard boot (1) ^ The shaft boot grooves Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9265 ^ The swage ring (2) Tighten each bolt of DT-47732 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 5. Install the spacer ring (2) on the shaft (1) in groove using J 8059. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9266 6. Slide the tripot joint spider assembly (3) toward the spacer ring (1) as far as it will go on the shaft (4). 7. Install the shaft retaining ring (2) in the groove of the shaft (4). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9267 8. Place approximately half of the grease from the service kit in the shaft inboard boot. Use the remainder of the grease to repack the housing. 9. Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). Install the trilobal tripot bushing (3) to housing. 10. Position the larger new boot retaining clamp (2) on the shaft inboard boot. 11. Slide the housing (1) over the tripot joint spider assembly on the shaft. 12. Slide the large diameter of the inboard boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove. 13. Important: The inboard boot must not be dimpled, stretched out or out of shape in any way. If the inboard boot is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Shape Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9268 the inboard boot properly by hand. Remove the tool. Position the joint assembly at dimension a = 107 mm (4.21 inch). 14. Align the following items while latching: ^ The seal (3) ^ The tripot housing (2) ^ The large seal retaining clamp Crimp the seal retaining clamp with J 35910 to 176 Nm (130 ft. lbs.). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary. ^ Verify dimension a = 2.15 mm (0.085 inch). 15. Fully stroke the joint several times to disperse the grease. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9269 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Seal Replacement Delphi Wheel Drive Shaft Outer Joint and Seal Replacement (Delphi) ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 41048 Drive Axle Swage Ring Clamp Removal Procedure 1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp. 2. Use a hand grinder to cut through the swage ring in order to remove the swage ring. 3. Separate the outboard seal from CV joint outer race (1) at large diameter. 4. Slide the seal (5) away from joint along shaft (4). 5. Wipe the grease from the face of the CV joint inner race (2). 6. Spread the ears on the race retaining ring (3) with J 8059. 7. Remove the CV joint assembly (1) from the shaft (4). 8. Remove the outboard seal (5) from the shaft (4). 9. Discard the old outboard seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9270 10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all 6 of the balls. 15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race. 16. Lift out the cage (4) and the inner race. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9271 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. ^ The inner and outer race assemblies ^ The CV joint cage ^ The chrome alloy balls 19. Dry all the parts. 20. Check the CV joint assembly for the following items: ^ Unusual wear ^ Cracks ^ Damage 21. Replace any damaged parts. 22. Clean the shaft. Use a wire brush to remove any rust in the grooves of the seal mounting area. Installation Procedure 1. Install the new swage ring (2) on the neck of the outboard seal (1). Do not swage. 2. Slide the outboard seal (1) onto the shaft and position the neck of the outboard seal (1) in the seal groove on the shaft. The largest groove below the sight groove on the shaft is the seal groove (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9272 3. The swage ring is swaged using J 41048 by the following method: 1. Position the outboard end of the wheel drive shaft assembly (1) in J 41048. 2. Align the swage ring. 3. Place the top half of J 41048 on the lower half of J 41048. 4. Notice: Refer to Fastener Notice in Service Precautions. Important: Align the following items during this procedure: ^ The outboard seal (1) ^ The shaft ^ The swage ring Insert the bolts (2) and tighten by hand until snug. Tighten each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9273 4. Loosen the bolts and separate the dies. 5. Check swaged ring (2) for any lip deformities. If present, place the ring (2) back into the J 41048 making sure the ring covers the whole swaging area. Then re-swage the ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9274 6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race. 7. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage. 8. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race. 9. Important: Verify that the retaining ring side of the inner race faces the shaft. Place the cage and the inner race into the outer race. 10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. 11. Repeat this process until all 6 balls are in place. 12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9275 13. Push the CV joint (2) onto the shaft (1) until the retaining ring is seated in the groove on the shaft. 14. Important: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9276 15. Crimp the seal retaining clamp (1) using J 35910. ^ Crimp the clamp (1) to 174 Nm (130 ft. lbs.). 16. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.Dimension a = 2.3 mm (3/32 inch). GKN Wheel Drive Shaft Outer Joint and Seal Replacement (GKN) ^ Tools Required J 41398 CV Puller - J 2619-01 Slide Hammer - J 35910 Drive Axle Seal Clamp Pliers - J 8039-A Snap Ring Pliers - DT-47732 Drive Axle Swage Ring Clamp Disassembly Procedure 1. Important: Due to the helical splines on the shaft, disassembly and assembly of the joints will be difficult. Follow the instructions provided. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the large seal retaining clamp. 2. Remove the small seal retaining clamp from the shaft with a side cutter and discard. 3. Separate the CV joint seal from the CV joint race (2) at the large diameter. 4. Slide the seal away from the joint along the shaft. 5. Wipe the grease from the face of the CV joint inner race (1). 6. Before removing the CV joint assembly from the half shaft bar, perform the following procedure: 1. Choose a reference mark (B) on the shaft. 2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9277 3. Mark as a reference the inboard side, toward the center of the half shaft bar, of the CV joint inner race (1). 4. Inspect the CV joint inner race/shaft interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A. 7. Clamp the shaft (2) into a vise. 8. Attach J 41398 to the threaded area of the outer race (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9278 9. Attach J 2619-01 onto the outer end of J 41398. 10. Use J 2619-01 to remove the CV joint from the shaft. 11. Remove J 2619-01 and J 41398 from the CV joint. 12. Important: Never reuse the retaining ring. Remove the retaining ring from the shaft. Discard the retaining ring. 13. Remove the CV joint seal (1) from the shaft. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9279 14. Place a brass drift against the CV joint cage (1). 15. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 18. Repeat this process to remove all 6 balls. 19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2). 20. Lift out the cage (4) and the inner race. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9280 21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 23. Dry all the parts. 24. Check the CV joint assembly for unusual wear, cracks, or other damage. 25. Replace any damaged parts. 26. Clean the shaft. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9281 1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race. 2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2). 3. Insert the inner race into the cage. 4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2). 5. Important: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier. Install the cage and the inner race into outer race. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9282 6. Place a brass drift against the CV joint cage (1). 7. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 9. Repeat this process to install all 6 balls. 10. Pack the CV joint with half of the grease supplied in the service kit. 11. Install the new swage ring (2) on the neck of the seal (3). Do not crimp. 12. Clean the shaft (1). Use a wire brush to remove any rust in the seal mounting area (grooves). 13. Slide the CV joint seal (3) onto the shaft (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the shaft (1) toward the tripot end. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9283 14. Position the large seal retaining clamp around the joint seal. 15. Place the new retaining ring onto the shaft. 16. While supporting the tripot assembly, place the wheel drive shaft assembly onto the arbor press with the CV assembly under the press head. 17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 1,779 N (4,000 lb) press load during assembly. 18. Remove the wheel drive shaft assembly from the arbor press. 19. Measure the distance between the reference mark on the shaft (B) and the face of the CV joint inner race (1). 20. Compare the mark with the measurement made before disassembly. 21. Repeat the previous 4 steps if the current measurement does not match the measurement made before disassembly. 22. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and the swage ring (2) onto the half shaft bar. 23. Position the small end of the boot (1) into the boot groove (3) on the half shaft bar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9284 24. Mount DT-47732 in a vise and proceed as follows: 1. Position the outboard end (1) of the wheel drive shaft assembly in tool. 2. Align the top of boot neck on the bottom die using the indicator. 3. Place the top half of the DT-47732 on the lower half of the DT-47732. 4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot. 5. Insert the bolts (2). 6. Tighten the bolts by hand until snug. 25. Notice: Refer to Fastener Notice in Service Precautions. Align the following items: ^ The shaft out board boot (1) ^ The shaft boot grooves Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 9285 ^ The swage ring (2) Tighten each bolt of DT-47732 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. Place the remaining grease from the service kit inside the seal. 26. Notice: Refer to Fastener Notice in Service Precautions. Mount DT-47732 in a vise and proceed as follows:Measure approximately 17.5 mm (11/16 inch) up from the bottom edge of the CV outer joint assembly. 27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint. 28. Important: The CV joint seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, equalize pressure in the seal and shape the seal properly by hand. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step. 29. Crimp seal retaining clamp (1) with J 35910, a breaker bar (3), and a torque wrench (2). ^ Tighten seal retaining clamp to 176 Nm (130 ft. lbs.). 30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a = 2.3 mm (0.091 inch). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9299 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9300 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 9301 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Wheel Bearing/Hub Assembly Mounting Bolts ...................................................................................................................................... 115 Nm (85 ft. lbs.) Rear Wheel Bearing/Hub Assembly Mounting Nuts ...................................................................................................................... 45 Nm +30° (33 ft. lbs. + 30°) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 9305 Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 9308 Wheel Bearing/Hub Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 9309 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Wheel Bearing/Hub Replacement - Rear (Disc Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the rear brake caliper and bracket as an assembly, and remove the rear brake rotor. 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the wheel bearing/hub assembly mounting nuts. 6. Remove the wheel bearing/hub assembly and the disc brake backing plate from the rear axle assembly. Installation Procedure 1. Install the wheel bearing/hub assembly and the brake backing plate to the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 9310 3. Connect the electrical connector to the wheel speed sensor. 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Drum Brake Wheel Bearing/Hub Replacement - Rear (Drum Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the plug from the drum brake actuator access hole in the backing plate. Using the access hole, install a support (1) for the brake backing plate. 5. Disconnect the electrical connector (2) from the wheel speed sensor, if equipped with ABS. 6. Remove the wheel bearing/hub assembly mounting nuts (3). 7. Remove the wheel bearing/hub assembly from the rear axle assembly and brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 9311 1. Install the wheel bearing/hub assembly to the brake backing plate and the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts (3) to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. 3. Connect the electrical connector (2) to the wheel speed sensor, if equipped with ABS. 4. Remove the support (1) from the brake backing plate. 5. Install the plug to the drum brake actuator access hole in the backing plate. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Nut ...................................................................................................................................... ................................................. 110 Nm (81 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate (AMT) Bolt First Pass ........................................................................................................... ........................................................................................ 53 Nm (39 ft. lbs.) Final Pass ..................... .............................................................................................................................................................. ........................... 25 degrees Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 9319 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. 2. Remove the flywheel bolts, and note the position of the flywheel to the crank shaft 3. Remove the flywheel. Installation Procedure 1. Position the flywheel on the crankshaft as previously noted. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the flywheel bolts. ^ Tighten the flywheel bolts to 53 Nm (39 ft. lbs.) plus 25 degrees. 3. Install the transmission. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel (SMT) Bolt First Pass ........................................................................................................... ........................................................................................ 53 Nm (39 ft. lbs.) Final Pass ..................... .............................................................................................................................................................. ........................... 25 degrees Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair Case: Service and Repair Rear Cover Replacement Removal Procedure 1. Remove the left front wheel. 2. Remove the rear cover bolts. 3. Remove the rear cover. 4. Inspect the oil guide for damage and replace as necessary. Installation Procedure 1. Install sealant Saturn P/N 21019581 to the rear cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair > Page 9327 2. Important: The oil guide only installs in one direction. Ensure the oil guide is completely seated in the gear shafts. Install the oil guide. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear cover. ^ Tighten the rear cover bolts to 25 Nm (18 ft. lbs.). 4. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 05560 > Sep > 05 > Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Fluid - M/T: Recalls Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Transmission Fluid Fill # 05560 - (Sep 15, 2005) Models: Certain 2005-06 Chevrolet Cobalt and Pontiac Pursuit (Canada only) Equipped with Getrag 5-Speed Manual Transmission (RPO M86) An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible, but no later than November 30, 2005, at which time this bulletin will expire. Condition Some late production 2005 and early production 2006 Chevrolet Cobalt and Pontiac Pursuit (Canada only) model vehicles with RPO M86 5 Speed manual transmissions were not filled with the specified Dexron III transmission fluid. Correction Dealers are to replace the transmission fluid in dealer stock vehicles with Dexron III transmission fluid. Service Procedure Refer to SI document number 869140 for the manual transmission fluid replacement procedure. Parts Information Warranty Information Dealers This correction should be performed on all vehicles currently in your inventory that are included in the VIN list contained in the Administrative Message (GM US) Dealer Communication (Canada) prior to sale or delivery. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 05560 > Sep > 05 > Campaign Getrag 5 Speed M/T Fluid Fill (Canada) Fluid - M/T: All Technical Service Bulletins Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Transmission Fluid Fill # 05560 - (Sep 15, 2005) Models: Certain 2005-06 Chevrolet Cobalt and Pontiac Pursuit (Canada only) Equipped with Getrag 5-Speed Manual Transmission (RPO M86) An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible, but no later than November 30, 2005, at which time this bulletin will expire. Condition Some late production 2005 and early production 2006 Chevrolet Cobalt and Pontiac Pursuit (Canada only) model vehicles with RPO M86 5 Speed manual transmissions were not filled with the specified Dexron III transmission fluid. Correction Dealers are to replace the transmission fluid in dealer stock vehicles with Dexron III transmission fluid. Service Procedure Refer to SI document number 869140 for the manual transmission fluid replacement procedure. Parts Information Warranty Information Dealers This correction should be performed on all vehicles currently in your inventory that are included in the VIN list contained in the Administrative Message (GM US) Dealer Communication (Canada) prior to sale or delivery. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................................. 1.7L (1.8 Qt) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 9343 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................................. Dexron III Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Getrag 5 Speed Fluid - M/T: Service and Repair Getrag 5 Speed Transmission Fluid Replacement Draining Procedure 1. Remove the left front wheel. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting 3. Clean away all dirt and debris from the transmission fluid drain plug area. 4. Remove the drain plug. 5. Allow the system to drain. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission fluid drain plug, using pipe sealant Saturn P/N 21485278 or equivalent on the plug threads. ^ Tighten the transmission fluid drain plug to 38 Nm (28 ft. lbs.). Filling Procedure 1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the transmission fluid level check plug. 3. Fill the transmission with DEXRON-III transmission fluid Saturn P/N 21019223, until even with the bottom of the fill plug hole. 4. Install the level check plug. ^ Tighten the level check plug to 38 Nm (28 ft. lbs.). 5. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9346 Fluid - M/T: Service and Repair MU3 Transmission Fluid Replacement 1. Important: The manual transaxle is filled with fluid at the manufacturer and requires no routine oil changes. If it is determined that the fluid needs to be changed due to contamination or a similar issue, follow this procedure. Important: To ensure that all sediment within the transaxle is suspended in the fluid, the fluid should only be drained after it has reached a normal operating temperature of 88 - 93°C (190 200°F). Normal operating temperature is reached after approximately 25 km (15 miles) of highway driving. Position vehicle on hoist and raise vehicle. Refer to Vehicle Lifting 2. Caution: The transaxle fluid is hot. Caution must be taken to prevent personal injury when the transaxle fluid drains from the transaxle. Remove the transaxle drain plug (1). 3. Remove the transaxle level plug (2). 4. Clean and apply thread sealant P/N 21485278 to the drain plug (1) and install. ^ Tighten the transaxle drain plug to 50 Nm (37 ft. lbs.). 5. Using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle lubricant P/N 21018899 through the level plug (2) opening until fluid flows out. 6. Clean and apply thread sealant P/N 21485278 to the level plug (2) and install. ^ Tighten the transaxle level plug to 50 Nm (37 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 07-07-29-001A > Apr > 07 > M/T - Growling/Grinding Noise in 3rd/4th Gear Output Shaft: Customer Interest M/T - Growling/Grinding Noise in 3rd/4th Gear Bulletin No.: 07-07-29-001A Date: April 16, 2007 TECHNICAL Subject: MG3, M86 Manual Transaxle Grinding or Growling Noise in 3rd or 4th Gear, Excessive Engagement or Disengagement Effort While Shifting into 5th or Reverse Gear, Will Not Shift into Either 5th or Reverse Gear (Replace Complete Output Shaft Assembly) Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2003-2007 Saturn ION, VUE with Getrag(TM) 5-Speed Manual Transaxle (RPOs MG3, M86) Supercede: This bulletin is being updated to add additional information on 5th or reverse gear in the Subject, Condition and Cause sections of this bulletin. Please discard Corporate Bulletin Number 07-07-29-001 (Section 07 - Transmission/Transaxle - Manual Transmission). Condition Some customers may comment on any or all of the following conditions: A grinding or growling noise in 3rd or 4th gear. Excessive engagement/disengagement effort while shifting into 5th or reverse gear. The vehicle will not shift into either 5th or reverse gear. Cause Diagnosis of the concern will lead the technician to replace the 5th/reverse gear synchronizer assembly and/or the 5th/reverse gear blocking rings on the output shaft of the transaxle to correct the condition. In order to access either the synchronizer assembly, the blocking rings, or any other components on the output shaft, the 4th gear must first be removed from the output shaft and then reinstalled after parts have been replaced. The Service Manual procedure for output shaft assembly states that the 4th gear will install very tight. Some dealers have been unsuccessful in achieving the press loads required to completely seat the 4th gear on the output shaft during re-assembly, resulting in these dealers replacing the entire manual transaxle assembly. Correction Some technicians may have trouble when pressing gears on or off the output shaft of the Getrag(TM) MG3/M86 five-speed manual transaxle. The output shaft gears are not splined to the output shaft and are a very tight press fit. If diagnosis leads to replacement of any components on the output shaft, dealers should follow published Service Information (SI) procedures and use the appropriate special tools to correctly re-assemble the output shaft. Pressing Output Shaft Gears When pressing these gears on or off of the output shaft, care needs to be taken to ensure that the shaft is not nicked or have any burrs on it. (The shaft and gear need to be free of dirt or debris). Extreme care should be taken not to bind or cock the gear on the shaft. If this happens, press the gear back off the shaft and start over. Press loads can reach 2-3 tons on the 4th fixed gear and 12-17 tons on the 3rd fixed gear (both located on the output shaft). The 3rd and 4th speed gears (on the input shaft) come off with minimal pressure but if trying to remove the 5th fixed gear and the 3rd speed gears at the same time, press loads in excess of 20 tons will not move the gear. Gears need to be removed and installed one at a time. If dealers are not able to properly seat the 4th gear on the output shaft, a complete output shaft assembly for MG3 and M86 manual transaxles is being Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 07-07-29-001A > Apr > 07 > M/T - Growling/Grinding Noise in 3rd/4th Gear > Page 9358 released as a field fix and should be used rather than replacing the manual transaxle assembly. Part numbers for these output shaft assemblies and their applications are listed below: Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 07-07-29-001A > Apr > 07 > M/T - Growling/Grinding Noise in 3rd/4th Gear Output Shaft: All Technical Service Bulletins M/T - Growling/Grinding Noise in 3rd/4th Gear Bulletin No.: 07-07-29-001A Date: April 16, 2007 TECHNICAL Subject: MG3, M86 Manual Transaxle Grinding or Growling Noise in 3rd or 4th Gear, Excessive Engagement or Disengagement Effort While Shifting into 5th or Reverse Gear, Will Not Shift into Either 5th or Reverse Gear (Replace Complete Output Shaft Assembly) Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2003-2007 Saturn ION, VUE with Getrag(TM) 5-Speed Manual Transaxle (RPOs MG3, M86) Supercede: This bulletin is being updated to add additional information on 5th or reverse gear in the Subject, Condition and Cause sections of this bulletin. Please discard Corporate Bulletin Number 07-07-29-001 (Section 07 - Transmission/Transaxle - Manual Transmission). Condition Some customers may comment on any or all of the following conditions: A grinding or growling noise in 3rd or 4th gear. Excessive engagement/disengagement effort while shifting into 5th or reverse gear. The vehicle will not shift into either 5th or reverse gear. Cause Diagnosis of the concern will lead the technician to replace the 5th/reverse gear synchronizer assembly and/or the 5th/reverse gear blocking rings on the output shaft of the transaxle to correct the condition. In order to access either the synchronizer assembly, the blocking rings, or any other components on the output shaft, the 4th gear must first be removed from the output shaft and then reinstalled after parts have been replaced. The Service Manual procedure for output shaft assembly states that the 4th gear will install very tight. Some dealers have been unsuccessful in achieving the press loads required to completely seat the 4th gear on the output shaft during re-assembly, resulting in these dealers replacing the entire manual transaxle assembly. Correction Some technicians may have trouble when pressing gears on or off the output shaft of the Getrag(TM) MG3/M86 five-speed manual transaxle. The output shaft gears are not splined to the output shaft and are a very tight press fit. If diagnosis leads to replacement of any components on the output shaft, dealers should follow published Service Information (SI) procedures and use the appropriate special tools to correctly re-assemble the output shaft. Pressing Output Shaft Gears When pressing these gears on or off of the output shaft, care needs to be taken to ensure that the shaft is not nicked or have any burrs on it. (The shaft and gear need to be free of dirt or debris). Extreme care should be taken not to bind or cock the gear on the shaft. If this happens, press the gear back off the shaft and start over. Press loads can reach 2-3 tons on the 4th fixed gear and 12-17 tons on the 3rd fixed gear (both located on the output shaft). The 3rd and 4th speed gears (on the input shaft) come off with minimal pressure but if trying to remove the 5th fixed gear and the 3rd speed gears at the same time, press loads in excess of 20 tons will not move the gear. Gears need to be removed and installed one at a time. If dealers are not able to properly seat the 4th gear on the output shaft, a complete output shaft assembly for MG3 and M86 manual transaxles is being Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 07-07-29-001A > Apr > 07 > M/T - Growling/Grinding Noise in 3rd/4th Gear > Page 9364 released as a field fix and should be used rather than replacing the manual transaxle assembly. Part numbers for these output shaft assemblies and their applications are listed below: Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Getrag 5 Speed Seals and Gaskets: Service and Repair Getrag 5 Speed Front Wheel Drive Shaft Oil Seal Replacement Front Wheel Drive Shaft Oil Seal Replacement ^ Tools Required J 44385Differential Bearing Race and Seal Installer - J 7079-2 Non-threaded Driver Handle - SA9133T Axle Seal Puller Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting 2. Remove the front wheel and tire assemblies. 3. Remove the wheel driveshaft. 4. Use the SA9133T in order to remove the seal. 5. Inspect the seal bore for nicks or for burrs. Clean the bore with a fine grade sandpaper, if necessary. Installation Procedure 1. Use the J 44385 and the J 7079-2 in order to install a new seal. Ensure that the seal is seated flush to the outer bore area. 2. Lubricate the seal with Dexron-III transmission fluid Saturn P/N 21019223. 3. Install the wheel driveshaft. 4. Install the front tire and wheel assemblies. 5. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Getrag 5 Speed > Page 9369 Axle Shaft Oil Seal Replacement Axle Shaft Oil Seal Replacement ^ Tools Required J 44385Differential Bearing Race and Seal Installer - J 7079-2 Non-threaded Driver Handle - SA9133T Axle Seal Puller Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting 2. Remove the front wheel and tire assemblies. 3. Remove the wheel driveshaft. 4. Use the SA9133T in order to remove the seal. 5. Inspect the seal bore for nicks or for burrs. Clean the bore with a fine grade sandpaper, if necessary. Installation Procedure 1. Use the J 44385 and the J 7079-2 in order to install a new seal. Ensure that the seal is seated flush to the outer bore area. 2. Lubricate the seal with Dexron-III transmission fluid Saturn P/N 21019223. 3. Install the wheel driveshaft. 4. Install the front tire and wheel assemblies. 5. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Getrag 5 Speed > Page 9370 Seals and Gaskets: Service and Repair MU3 Axle Seals Replacement ^ Tools Required SA9133T Axle Seal Puller Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting 2. Remove the front wheel and tire assemblies. 3. Remove the wheel driveshaft or intermediate drive shaft. 4. Use the SA9133T in order to remove the seal. 5. Inspect the seal bore for nicks or for burrs. Clean the bore with a fine grade sandpaper, if necessary. Installation Procedure 1. Use the SA9133T to install a new seal. Ensure that the seal is seated flush to the outer bore area. 2. Install the wheel driveshaft or intermediate drive shaft. 3. Install the front tire and wheel assemblies. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever Shifter M/T: Customer Interest M/T - Shifter Knob Loose/Detached From Shift Lever Bulletin No.: 05-07-29-006A Date: February 13, 2006 TECHNICAL Subject: Shifter Knob Loose or Detached From Shift Control Lever (Secure Shifter Knob with Adhesive and Fastener) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with 5-Speed Manual Transaxle (RPO MU3) Supercede: This bulletin is being revised to delete the WPC form. Parts are now available from GMSPO and Saturn SPO. Please discard Corporate Bulletin Number 05-07-29-006 (Section 07 Transmission/Transaxle). Condition Some customers may comment that the shift control knob (shifter knob) may be loose or detached from the shift control lever. Cause The interference fit between the shift control knob and the shift control lever may allow the shift control knob to become loose or detached. Correction Secure the original equipment or new service shift control knob to the shift control lever using adhesive and a self-tapping fastener. Service Procedure Important: Make sure the leather boot is still in place around the shift control lever base in order to prevent drilling debris from falling into the shifter mechanism. Important: Re-use the original equipment shifter knob whenever possible. Only use a new service shifter knob if the original equipment knob is damaged or missing. 1. Carefully remove the emblem from the original equipment shift control knob. Save this emblem for re-use if retaining the original equipment shift control knob or for re-use on the new service shift control knob, if applicable. Important: The service shifter knob may feel slightly "looser" than the production part. This is a normal characteristic. Do NOT replace the entire shift control assembly for this condition. 2. Place the shift control knob back on the shift control lever. Ensure that the shifter knob is correctly oriented. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 9383 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 9384 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever Shifter M/T: All Technical Service Bulletins M/T - Shifter Knob Loose/Detached From Shift Lever Bulletin No.: 05-07-29-006A Date: February 13, 2006 TECHNICAL Subject: Shifter Knob Loose or Detached From Shift Control Lever (Secure Shifter Knob with Adhesive and Fastener) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with 5-Speed Manual Transaxle (RPO MU3) Supercede: This bulletin is being revised to delete the WPC form. Parts are now available from GMSPO and Saturn SPO. Please discard Corporate Bulletin Number 05-07-29-006 (Section 07 Transmission/Transaxle). Condition Some customers may comment that the shift control knob (shifter knob) may be loose or detached from the shift control lever. Cause The interference fit between the shift control knob and the shift control lever may allow the shift control knob to become loose or detached. Correction Secure the original equipment or new service shift control knob to the shift control lever using adhesive and a self-tapping fastener. Service Procedure Important: Make sure the leather boot is still in place around the shift control lever base in order to prevent drilling debris from falling into the shifter mechanism. Important: Re-use the original equipment shifter knob whenever possible. Only use a new service shifter knob if the original equipment knob is damaged or missing. 1. Carefully remove the emblem from the original equipment shift control knob. Save this emblem for re-use if retaining the original equipment shift control knob or for re-use on the new service shift control knob, if applicable. Important: The service shifter knob may feel slightly "looser" than the production part. This is a normal characteristic. Do NOT replace the entire shift control assembly for this condition. 2. Place the shift control knob back on the shift control lever. Ensure that the shifter knob is correctly oriented. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 9390 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 9391 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Getrag 5 Speed Shifter M/T: Service and Repair Getrag 5 Speed Shift Control Knob Replacement Removal Procedure 1. Twist the shift control boot collar 1/4 turn and disconnect from the shift control boot (2). 2. Remove the shift control knob (1) upward from the shift control assembly. Installation Procedure 1. Install the shift control knob (1) to the shift control assembly. 2. Install the shift control boot collar (2) to the shift control knob (1) and twist 1/4 turn to lock. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9394 Shifter M/T: Service and Repair MU3 Shift Control Knob Replacement Removal Procedure 1. Important: Be careful of cosmetic damage to the emblem. In case of damage, replace the emblem with a new part. Remove the emblem (1) from the top of the shifter knob. 2. Cut away the runner protector in the center. 3. Mark and drill a 4 mm hole 5 mm deep into the knob, 3 mm from the edge (1) as shown. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9395 4. The knob can be removed by screwing a self-threading plate screw with a flat tip (25 x 5.5 mm) into the hole. 5. Remove the shifter knob (3) from the shiftier spline (2) and shifter assembly (1). Installation Procedure 1. Important: Use adhesive 24 96 292 thread locking adhesive. Apply adhesive to the knob. 2. Seat the shifter knob over the shifter lever. Ensure the spring and foam rings are correctly seated. 3. Important: Do not operate the lever until the adhesive has dried (approximately 30 minutes). Position and fit the emblem over the shifter knob. 4. Vacuum and clean any debris. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair Shift Boot: Service and Repair Shift Control Boot Replacement Removal Procedure 1. Remove the shift control knob. 2. Pry up on the shift control boot trim from the front of the shift control boot assembly. 3. Remove the shift control boot. Installation Procedure 1. Install the shift control boot to the vehicle. 2. Install the shift control boot trim to the console assembly. 3. Install the shift control knob. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Getrag 5 Speed Shift Cable: Adjustments Getrag 5 Speed Shift Cable Adjustment 1. Set the parking brake. 2. Remove the cup holder. 3. Lift and unlock the shift cable retainers. 4. Push the shifter neutral lock clip. Move the shifter slightly in order to center the lock clip. 5. Ensure that the transmission is in neutral. 6. Press and lock the shift cable retainers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Getrag 5 Speed > Page 9404 7. Pull the shifter neutral lock clip to its original position. 8. Install the cup holder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Getrag 5 Speed > Page 9405 Shift Cable: Adjustments MU3 Shift Cable Adjustment 1. Set the parking brake. 2. Remove the cup holder. 3. Lift and unlock the shift cable retainers. 4. Push the shifter 4th gear lock clip. Move the shifter slightly in order to center the lock clip. 5. Ensure that the transmission is in 4th gear. 6. Press and lock the shift cable retainers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Getrag 5 Speed > Page 9406 7. Pull the shifter 4th gear lock clip to its original position. 8. Install the cup holder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed Shift Cable: Service and Repair Getrag 5 Speed Shift Cable Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission to neutral (N). 3. Remove the console. 4. Lift up the cable retainers. 5. Disconnect cable ends from the shift control assembly, noting the location for assembly. 6. Disconnect the cable ends from the transmission shift levers, noting the location for assembly. 7. Remove the shift cable from the transmission cable bracket. 8. Raise and support the vehicle. Refer to Vehicle Lifting 9. Remove the shift cable attachment nut from the underbody. 10. Lower the vehicle. 11. Remove the left instrument panel closeout panel. 12. Position the drivers side front carpet aside. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9409 13. Separate the grommet (1) from the floor pan. 14. Remove the cable from the vehicle by pulling the cables through the drivers floor opening. Installation Procedure 1. Feed the cable assembly through the drivers floor opening. 2. Install the grommet (1) flush with the floor opening. 3. Install the drivers side front carpet. 4. Install the left instrument panel closeout panel. 5. Raise the vehicle. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the shift cable attachment nut to the underbody. ^ Tighten the nut to 10 Nm (89 inch lbs.). 7. Lower the vehicle. 8. Install the shift cables to the transmission cable bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9410 9. Connect the shift cable ends to the transmission shift levers as noted during disassembly. 10. Connect the shift cable to the shift control assembly as noted during disassembly. 11. Push the shifter neutral lock clip. Move the shifter slightly in order to center the lock clip. 12. Ensure that the transmission is in neutral. 13. Press down on the locking tabs. 14. Pull the shifter neutral lock clip to its original position. 15. Install the console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9411 Shift Cable: Service and Repair MU3 Shift Control Cable Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission to 4th gear. 3. Remove the console. 4. Lift up the cable retainers. 5. Disconnect cable ends from the shift control assembly, noting the location for assembly. 6. Disconnect the cable ends (1) from the transmission shift levers, noting the location for assembly. 7. Remove the shift cable (2) from the transmission cable bracket. 8. Raise and support the vehicle. Refer to Vehicle Lifting 9. Remove the shift cable attachment nut from the underbody. 10. Lower the vehicle. 11. Remove the left instrument panel closeout panel. 12. Position the drivers side front carpet aside. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9412 13. Separate the grommet (1) from the floor pan. 14. Remove the cable from the vehicle by pulling the cables through the drivers floor opening. Installation Procedure 1. Feed the cable assembly through the drivers floor opening. 2. Install the grommet (1) flush with the floor opening. 3. Install the drivers side front carpet. 4. Install the left instrument panel closeout panel. 5. Raise the vehicle. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the shift cable attachment nut to the underbody. ^ Tighten the nut to 10 Nm (89 inch lbs.). 7. Lower the vehicle. 8. Install the shift cables (2) to the transmission cable bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9413 9. Connect the shift cable ends (1) to the transmission shift levers as noted during disassembly. 10. Connect the shift cable to the shift control assembly as noted during disassembly. 11. Push the shifter 4th gear locking tab. 12. Ensure that the transmission is in 4th gear. 13. Press down on the locking tabs. 14. Pull the shifter 4th gear lock clip to its original position. 15. Install the console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed Transmission Mount: Service and Repair Getrag 5 Speed Transmission Mount Replacement - Front Transmission Mount Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the front transaxle mount thru bolt. 3. Remove the front transaxle mount to transaxle bolts. 4. Remove the front transaxle mount from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9418 1. Important: The transaxle bolts must be torqued in a mandatory sequence as shown. Notice: Refer to Fastener Notice in Service Precautions. Install the front transaxle mount and transaxle bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 2. Hand start the front transaxle mount through bolt. 3. Important: The front and rear transaxle mounts must be allowed to settle with the through bolts loosened. Loosen the rear transaxle mount through bolt. 4. ^ Tighten the transaxle mount through bolts in the following order: 1. Tighten the rear bolt to 100 Nm (74 ft. lbs.). 2. Tighten the front bolt to 100 Nm (74 ft. lbs.). 5. Lower the vehicle. Transmission Mount Replacement - Rear Transmission Mount Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9419 2. Remove the rear transaxle mount through bolt and heat shield. 3. Remove the rear transaxle mount to frame bolts. 4. Remove the rear transaxle mount. Installation Procedure 1. Install the rear transaxle mount and heat shield. Hand start the bolts. 2. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9420 Tighten the rear transaxle mount to frame bolts. ^ Tighten the bolts to 60 Nm (44 ft. lbs.). 3. Important: Rotate the rear transaxle mount heat shield clockwise until the tab is seated on the mount bracket. Hand start the rear transaxle mount through bolt. 4. Important: The front and rear transmission mounts must be allowed to settle with the through bolts loosened. Loosen the front trans mount through bolt. 5. Tighten the transmission mount through bolts in the following order: 1. Tighten the rear bolt to 100 Nm (74 ft. lbs.). 2. Tighten the front bolt to 100 Nm (74 ft. lbs.). 6. Lower the vehicle. Transmission Mount Replacement - Left Transmission Mount Replacement - Left Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the underhood electrical center cover. 3. Disconnect the engine control module (ECM) harness connector (3, 4). 4. Disconnect the positive battery cables (1) from the underhood electrical center. 5. Disconnect the surge tank inlet hose from the surge tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9421 6. Remove the underhood electrical center tray bracket nuts (1, 2) and bolt (3). 7. Disconnect the wiring harness retainer from the tray bracket. 8. Lift the electrical center up and swing it back and out of the way. 9. Support the transmission with a floor jack. Use a piece of wood between the jack and the transmission. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9422 10. Remove the transmission mount to transmission bolts. 11. Remove the transmission mount to mid-rail bolts. 12. Using a floor jack, slowly lower the transmission enough to remove the transmission mount from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9423 1. Install the transmission mount to the mid-rail. 2. Notice: Refer to Fastener Notice in Service Precautions. Hand start the transmission mount to mid-rail bolts. ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 3. Using a floor jack, raise the transmission until it contacts the transmission mount. 4. Important: The transmission mount to transmission bolts must be hand started. Do not pry the transmission or mount to align the holes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9424 Hand start the transmission mount to transmission bolts using the following sequence: 1. Rear bolt 2. Middle bolt 3. Front bolt 5. Using the previous sequence, tighten the transmission mount bolts. ^ Tighten the bolts to 45 Nm (33 ft. lbs.). 6. Reposition the underhood electrical center. 7. Connect the wiring harness to the tray bracket. 8. Install the electrical center nuts (1, 2) and bolt (3). ^ Tighten the nuts to 10 Nm (89 inch lbs.). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 9. Connect the surge tank inlet hose to the surge tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9425 10. Install the positive battery cables (1) to the underhood electrical center. ^ Tighten the positive cable nut to 15 Nm (11 ft. lbs.). 11. Connect the engine control module harness connectors (3, 4). 12. Connect the negative battery cable. 13. Install the underhood electrical center cover. Transmission Mount Bracket Replacement - Rear Transmission Mount Bracket Replacement - Rear Removal Procedure 1. Remove the rear transaxle mount. 2. Remove the axle boot heat shield bolts. 3. Remove the axle boot heat shield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9426 4. Remove the rear transaxle mount bracket to transaxle bolts. 5. Remove the rear transaxle mount bracket from the transaxle. Installation Procedure 1. Install the rear transaxle mount to transaxle. 2. Notice: Refer to Fastener Notice in Service Precautions. Using the following sequence, install the rear transaxle mount bracket bolts: 1. Tighten the middle bolt to 60 Nm (44 ft. lbs.). 2. Tighten the lower bolt to 60 Nm (44 ft. lbs.). 3. Tighten the upper bolt to 60 Nm (44 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9427 3. Install the axle boot heat shield. 4. Install the axle boot heat shield bolts. ^ Tighten the heat shield to transmission mount bracket bolt to 10 Nm (89 inch lbs.). ^ Tighten the heat shield to engine bolt to 30 Nm (22 ft. lbs.). 5. Install the rear transaxle mount. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9428 Transmission Mount: Service and Repair MU3 Transmission Mount Replacement - Front Transmission Mount Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the front transaxle mount through bolt. 3. Remove the front transaxle mount to transaxle bolts. 4. Remove the front transaxle mount from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9429 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front transaxle mount to the transaxle bolts, and tighten in sequence. ^ Tighten the bolts to 90 Nm (66 ft. lbs.). 2. Hand start the front transaxle mount through bolt. 3. Important: The front and rear transaxle mounts must be allowed to settle with the through bolts loosened. Loosen the rear transaxle mount through bolt. 4. Tighten the transaxle mount through bolts in the following order: 1. Tighten the rear bolt to 100 Nm (74 ft. lbs.). 2. Tighten the front bolt to 100 Nm (74 ft. lbs.). 5. Lower the vehicle. Transmission Mount Replacement - Rear Transmission Mount Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9430 2. Remove the rear transaxle mount thru bolt and heat shield. 3. Remove the rear transaxle mount to frame bolts. 4. Remove the rear transaxle mount. Installation Procedure 1. Install the rear transaxle mount to frame bolts. Hand tighten the bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9431 2. Install the rear transaxle mount, heat shield and the thru bolt to the transmission bracket. Hand tighten the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Tighten the rear transaxle mount to frame bolts. ^ Tighten the bolts to 60 Nm (44 ft. lbs.). 4. Important: Rotate the rear transaxle mount heat shield clockwise until the tab is seated on the mount bracket. Important: The front and rear transmission mounts must be allowed to settle with the thru bolts loosened. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9432 Loosen the front transaxle mount thru bolt but do not remove the bolt. 5. Tighten the rear transmission mount thru bolt. ^ Tighten the thru bolt to 100 Nm (74 ft. lbs.). 6. Tighten the front transmission mount thru bolt. ^ Tighten the thru bolt to 100 Nm (74 ft. lbs.). 7. Lower the vehicle. Transmission Mount Replacement - Left Transmission Mount Replacement - Left Removal Procedure 1. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9433 2. Support the transmission with a floor jack. Use a piece of wood between the jack and the transmission. 3. Remove the transmission mount-to-transmission bracket bolts. 4. Remove the transmission mount to mid-rail bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9434 5. Using a floor jack, slowly lower the transmission enough to remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the mid-rail. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to mid-rail bolts. ^ Tighten the bolts to 27 Nm (20 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Getrag 5 Speed > Page 9435 3. Using a floor jack, raise the transmission until it contacts the transmission mount. 4. Important: The transmission mount to transmission bolts must be hand started. Do not pry the transmission or mount to align the holes. Hand start the transmission mount to bracket bolts using the following sequence: 1. Rear bolt 2. Middle bolt 3. Front bolt 5. Using the previous sequence, tighten the transmission mount bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 6. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 9442 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 9448 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 9449 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 9453 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 9454 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9463 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9464 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9465 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9471 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9472 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9473 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9477 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9478 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9479 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9480 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9481 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9485 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 9499 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 9500 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 9507 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 9508 Shift Solenoid: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 9509 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 9512 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 9516 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 9517 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information Control Module: Technical Service Bulletins A/T Controls -Transmission Control Module Information INFORMATION Bulletin No.: 05-07-30-016C Date: October 07, 2009 Subject: Transmission Control Module (TCM) Shorted To Battery Voltage During Diagnosis, Service or Jump-Starting Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2006-2010 Chevrolet Express 2006-2010 GMC Savana 2005-2006 Pontiac Pursuit (Canada) 2007-2010 Pontiac G5 2005-2007 Saturn ION with 4T40-E or 4T45-E or 4L60-E Automatic Transmission (RPO MN4, MN5, M30) Supercede: This bulletin is being revised to add models and update the model years. Please discard Corporate Bulletin Number 05-07-30-016B (Section 07 - Transmission/Transaxle). It has been found during warranty part reviews of the TCM at the Warranty Parts Center (WPC) that the TCM is possibly being shorted to battery voltage during vehicle diagnosis and/or repairs when the vehicle is brought to the dealer for any number of reasons. It has been found that if the positive battery jump start post/terminal cover is removed and/or missing, and the TCM comes in contact with the positive battery jump start post/terminal during diagnosis and/or service, the TCM WILL BE DAMAGED and require replacement. Service Precautions - Prior to removing the TCM from its mounting bracket, disconnect the negative battery cable. Refer to the appropriate SI Document. - If service requires the negative battery cable to be installed for diagnostic purposes, unplug the TCM before it is removed from its mounting bracket. Unplugging the TCM will eliminate the possibility of damaging the module during diagnosis and/or repair. Caution Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle's battery. DO NOT us the TCM or its mounting bracket/fasteners as the ground connection when jump-starting. DO NOT allow the TCM to come in contact with the positive battery jump start post/terminal during diagnosis and/or repairs. Do NOT allow any part of the TCM to come into contact with the positive battery jump start post/terminal. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T Controls -Transmission Control Module Information > Page 9524 Control Module: Technical Service Bulletins Engine, A/T Controls - Shared Diagnostic Trouble Codes Bulletin No.: 05-06-04-060 Date: September 23, 2005 INFORMATION Subject: Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM) Diagnostic Trouble Code(s) (DTC)(s) P0601, P0602, P0603, P0604, P1621 Shared In Multiple Modules Models: 2005-2006 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Beginning in 2005, some control modules (ECM's, TCM's) have specific codes that describe internal failures of the module. These DTCs are not module specific and can be found on any controller that has these codes. Society of Automotive Engineers (SAE) J2012 committee has set these specific codes to be an industry standard of all manufacturers. Currently, these common codes are: ^ P0601 - Control Module Read Only Memory (ROM) ^ P0601 - Transmission Control Module (TCM) Read Only Memory (ROM) ^ P0602 - Control Module Not Programmed ^ P0602 - Transmission Control Module (TCM) Not Programmed ^ P0603 - Control Module Long Term Memory Reset ^ P0603 - Transmission Control Module (TCM) Long Term Memory Reset ^ P0604 - Control Module Random Access Memory (RAM) ^ P0604 - Transmission Control Module (TCM) Random Access Memory (RAM) ^ P1621 - Control Module Long Term Memory Performance ^ P1621 - Transmission Control Module (TCM) Long Term Memory Performance Important: ^ Use caution when diagnosing these shared codes to perform the appropriate diagnostic procedure on the appropriate module. ^ A low voltage condition may set one or more of the above codes. Repair any low voltage conditions prior to diagnosing the above codes. Refer to the appropriate Service Information (SI) document for Diagnosis and Repair procedures. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 9530 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 9531 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 9535 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 9536 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. 2. Notice: Install the six bolts to the TFP switch assembly. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9545 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9546 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9547 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9553 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9554 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 9555 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments Transmission Position Switch/Sensor: Adjustments Park/Neutral Position (PNP) Switch Adjustment ^ Tools Required J 41545 Park/Neutral Switch Aligner Adjustment 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9559 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9560 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position (PNP) Switch Replacement ^ Tools Required J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. 4. Remove the transaxle range switch lever nut and lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9561 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. 5. Notice: Tighten the transaxle range switch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9562 ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 6. Remove the alignment tool. 7. Install the transaxle range switch lever and nut ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 8. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Page 9563 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Notice: Tighten the transaxle range switch bolts. ^ Tighten the range switch bolts to 20 Nm (15 ft. lbs.). 4. Install the transaxle range switch lever and nut. ^ Tighten the transaxle range switch lever retaining nut to 35 Nm (26 ft. lbs.). 5. Important: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. Install the shift control cable to transaxle range switch lever and verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Automatic Transmission Electronic Component Views Electronic Components Electronic Components 13 - TFP Manual Valve Position Switch Assembly 46 - Input Speed Sensor 62 - Output Speed Sensor 305 - 1-2 and 2-3 Shift Solenoid Valves 305 - 1-2 and 2-3 Shift Solenoid Valves 312 Pressure Control Solenoid 335 - TCC Control PWM Solenoid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9567 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Remove the left front wheel. 2. Disconnect the backup lamp connector (1). 3. Remove the backup lamp switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. using pipe sealant Saturn P/N 21485278 or equivalent. ^ Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector (1). 3. Install the left front wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9585 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9586 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9592 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9593 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9594 Electronic Brake Control Module: Locations ABS Component Views 1 - Transmission Control Module (TCM) (MN5) 2 - LF Strut Tower 3 - Engine Control Module (ECM) (L61) 4 - Electronic Brake Control Module (EBCM) (JM4/JL9) 5 - Fuse Block - Underhood Bracket Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9595 Electronic Brake Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9597 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. If equipped with RPO LSJ, remove the throttle body air snorkel. 3. Clean the electronic brake control module (EBCM) (3) to brake pressure modulator valve (BPMV) (4) area of any accumulated dirt and foreign material. 4. Disconnect the electrical connector (1) from the EBCM (3). 5. Remove the 4 EBCM-to-BPMV retaining bolts (2). 6. Important: Do Not use a metal tool to pry the EBCM from the BPMV. Use care to ensure that the EBCM-to-BPMV mating surfaces are not scratched during EBCM removal. Separate the EBCM (3) from the BPMV (4) by carefully pulling apart. Installation Procedure 1. Clean the EBCM mating surface of the BPMV (4), with denatured alcohol, or equivalent. 2. Ensure that the EBCM (3) to BPMV (4) seal is fully seated in the groove on the EBCM (3). 3. Install the EBCM (3) to the BPMV (4). Use care when aligning the EBCM (3) to the BPMV electrical terminals (4). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 EBCM-to-BPMV retaining bolts (2). Tighten the bolts in a criss-cross pattern. ^ Tighten the bolts to 4.5 Nm (40 inch lbs.). 5. Connect the electrical connector (1) to the EBCM (3). 6. If equipped with RPO LSJ, install the throttle body air snorkel. 7. If a new EBCM was installed, the EBCM must be programmed. 8. Turn the ignition switch to the ON position. DO NOT start engine. 9. Perform the Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9602 Brake Pressure Modulator Valve (BPMV) Bracket Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9603 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9604 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9605 Brake Pressure Modulator Valve (BPMV) Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9614 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9615 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9621 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 9622 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9628 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9629 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9630 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9635 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9636 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9637 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9638 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9639 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9640 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 9645 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9650 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9656 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9657 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9658 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9663 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9664 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9665 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9666 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9667 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9668 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 9673 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 9678 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensors (JM4/JL9) Wheel Speed Sensors (JM4/JL9) 1 - Wheel Speed Sensor (WSS) - LF 2 - Wheel Speed Sensor (WSS) - RF 3 - Wheel Speed Sensor (WSS) - RR 4 - Wheel Speed Sensor (WSS) - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 9682 Wheel Speed Sensor: Diagrams Wheel Speed Sensor - LF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 9683 Wheel Speed Sensor - RF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 9684 Wheel Speed Sensor - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 9685 Wheel Speed Sensor - RR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base brake system. The automated bleed procedure is recommended when one of the following conditions exist: ^ Base brake system bleeding does not achieve the desired pedal height or feel ^ Extreme loss of brake fluid has occurred ^ Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure 1. Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. Raise and support the vehicle. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. 10. Following the directions given on the scan tool, pressure bleed the base brake system. 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle, and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. 17. Inspect the brake fluid level. 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9690 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 21. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9691 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice; When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532, or equivalent, to the J 44894-A. 7. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 8. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks.Any brake fluid leaks identified require repair prior to completing this procedure. 10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 20. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 44894-A. 21. Remove the J 44894-A from the brake master cylinder reservoir. 22. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9692 2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). 24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 25. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9693 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir, if bleeding from a manual transmission vehicle ensure to cap or plug the clutch hose port while bleeding the master cylinder. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Release the electric power steering (EPS) wiring harness from the brake pedal bracket. 2. Release the accelerator pedal position (APP) sensor jumper harness from the brake pedal bracket. 3. Disconnect the electrical connector from the APP sensor. 4. Loosen the brake booster mounting nuts. 5. Remove the retaining clip (4) and washer (3) from the brake pedal. 6. Release the brake booster pushrod (2) from the brake pedal. 7. Remove the brake booster mounting nuts. 8. Remove the brake pedal bracket-to-steering column bracket bolt (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 9697 9. Lower the brake pedal assembly to improve access for switch removal. 10. Remove the stop lamp switch from the pedal bracket. 11. Remove the cruise control release switch, if equipped, from the pedal bracket. 12. Remove the brake pedal assembly, with the accelerator pedal assembly from the vehicle. 13. Remove the accelerator pedal mounting bolts and remove the pedal assembly. Installation Procedure 1. Position the accelerator pedal assembly to the brake pedal bracket. 2. Notice: Install the accelerator pedal and sensor assembly mounting bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 9698 ^ Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the brake pedal assembly, with the accelerator pedal assembly to the vehicle. 4. Install the cruise control release switch, if equipped, to the pedal bracket. 5. Install the stop lamp switch to the pedal bracket. 6. Move the brake pedal assembly to the installed position. 7. Install the brake pedal bracket-to-steering column bracket bolt (1). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 8. Loosely install the brake booster mounting nuts. 9. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal. 10. Connect the brake booster pushrod (2) to the brake pedal. 11. Install the washer (3) and retaining clip (4) to the brake pedal. 12. Tighten the vacuum brake booster mounting nuts. ^ Tighten the nuts to 17 Nm (14 ft. lbs.). 13. Adjust the stop lamp switch. 14. Adjust the cruise control release switch, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 9699 15. Connect the electrical connector to the APP sensor. 16. Secure the APP sensor jumper harness to the brake pedal bracket. 17. Secure the EPS wiring harness to the pedal bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9715 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9716 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9717 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9724 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9725 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9726 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9728 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9732 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9733 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9734 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9735 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9749 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9750 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9751 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9752 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9753 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9754 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9755 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9756 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9757 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9758 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9759 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9760 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9761 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9762 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9763 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9764 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9765 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9766 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9767 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9768 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9769 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9770 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9771 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9772 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9773 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9774 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9775 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9776 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9777 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9778 Brake Warning Indicator: Electrical Diagrams Brake Warning System Schematics Brake Warning System Diagram Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9779 Locations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9785 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (1). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the brake caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper guide pin bolts (1). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9786 3. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 4. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9787 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9788 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). 8. Important: Do not use abrasives to clean the brake caliper piston. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal (4) with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9789 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the bleeder valve to the caliper. ^ Tighten the brake bleeder valve to 11 Nm (97 inch lbs.). 10. Install the bleeder valve cap. 11. Install the brake caliper to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9790 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 5. Release the tension from the park brake cables.With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the tire and wheel assembly. 8. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 9. Release the park brake cable end (1) from the lever on the caliper. 10. Release the retaining tabs (4) securing the park brake cable to the bracket on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9791 11. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 12. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 13. Remove the C-clamp from the caliper. 14. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 15. Remove the brake hose (3) from the brake caliper. 16. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 17. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 18. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9792 19. Remove the brake caliper from the caliper bracket. 20. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 21. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4). 4. Secure the park brake cable end (1) to the lever on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9793 5. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 6. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Remove the wheel nuts retaining the brake rotor to the wheel hub. 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Adjust the park brake cable tension. 16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9794 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the rear brake caliper from vehicle. 2. Important: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and into the non-serviceable integral park brake mechanism. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9795 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism: Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. 9. Important: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. If the integral park brake mechanism was not operating properly, binding or seized, replace the brake caliper assembly. 10. Important: Do not use abrasives to clean the brake caliper piston. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 13. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 14. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. 15. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 16. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9796 3. Install the new dust boot seal onto the caliper piston (2). 4. Insert the caliper piston into the caliper bore. Using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). 5. Fully seat the piston dust boot seal in the seal counterbore. 6. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 7. Install the brake caliper to the vehicle. Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9797 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9798 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (1). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the brake caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper guide pin bolts (1). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9799 3. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 4. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9800 pistons are blown out, even with the padding provided, it may be damaged. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). 8. Important: Do not use abrasives to clean the brake caliper piston. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9801 1. Lubricate the new piston seal (4) with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the bleeder valve to the caliper. ^ Tighten the brake bleeder valve to 11 Nm (97 inch lbs.). 10. Install the bleeder valve cap. 11. Install the brake caliper to the vehicle. Brake Caliper Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9802 Brake Caliper Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 5. Release the tension from the park brake cables.With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the tire and wheel assembly. 8. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 9. Release the park brake cable end (1) from the lever on the caliper. 10. Release the retaining tabs (4) securing the park brake cable to the bracket on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9803 11. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 12. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 13. Remove the C-clamp from the caliper. 14. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 15. Remove the brake hose (3) from the brake caliper. 16. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 17. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 18. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9804 19. Remove the brake caliper from the caliper bracket. 20. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 21. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4). 4. Secure the park brake cable end (1) to the lever on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9805 5. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 6. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Remove the wheel nuts retaining the brake rotor to the wheel hub. 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Adjust the park brake cable tension. 16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the rear brake caliper from vehicle. 2. Important: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9806 into the non-serviceable integral park brake mechanism. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism: Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. 9. Important: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. If the integral park brake mechanism was not operating properly, binding or seized, replace the brake caliper assembly. 10. Important: Do not use abrasives to clean the brake caliper piston. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 13. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 14. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9807 15. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 16. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the new dust boot seal onto the caliper piston (2). 4. Insert the caliper piston into the caliper bore. Using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9808 5. Fully seat the piston dust boot seal in the seal counterbore. 6. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 7. Install the brake caliper to the vehicle. Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (2), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9809 2. Remove the brake pads from the brake caliper bracket. 3. Remove the brake pad retainers (1) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 5. Inspect the disc brake pad retainers (1) for the following: ^ Bent mounting tabs ^ Excessive corrosion ^ Looseness at the brake caliper mounting bracket ^ Looseness at the disc brake pads 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the steering knuckle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9810 9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (5). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper mounting bracket to the steering knuckle. 2. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts (1). ^ Tighten the bolts to 115 Nm (85 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9811 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 4. Clean the brake pad mating surfaces of the brake pad retainers (1). 5. Install the brake pad retainers (1) to the brake caliper bracket. 6. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. Install the brake pads to the brake caliper bracket. 7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads from the brake caliper bracket. 3. Remove the brake pad retainers (1) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 5. Inspect the disc brake pad retainers (1) for the following: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9812 ^ Bent mounting tabs ^ Excessive corrosion ^ Looseness at the brake caliper mounting bracket ^ Looseness at the disc brake pads 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the rear axle. 9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9813 1. Install the brake caliper mounting bracket to the rear axle. 2. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts (1). ^ Tighten the bolts to 115 Nm (85 ft. lbs.). 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 4. Clean the brake pad mating surfaces of the brake pad retainers (1). 5. Install the brake pad retainers (1) to the brake caliper bracket. 6. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the bottom of the pad when installed in vehicle position. Install the brake pads to the brake caliper bracket. 7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake Pad Lining Minimum Thickness ................................................................................................................................................. 1.0 mm (0.039 inch) Brake Pad Lining Thickness - New ..................................................................................................................................................... 12.0 mm (0.472 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front Brake Pad: Service and Repair Brake Pads Replacement - Front Brake Pads Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outboard brake pad. 8. Tighten the C-clamp evenly until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Remove the brake caliper lower guide pin bolt (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9819 11. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire (1), or equivalent. 12. Remove the brake pads from the caliper mounting bracket. 13. Remove the brake pad retainers (1) from the caliper bracket. 14. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 15. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 16. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9820 17. Install a large C-clamp (1) over the body of the brake caliper (3), with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad (2) or a wood block installed against the caliper piston. 18. ^ Tighten the C-clamp (1) evenly until the caliper piston is compressed completely into the caliper bore. 19. Remove the C-clamp and the old brake pad or wood block from the caliper. Installation Procedure 1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 2. Install the brake pad retainers (1) to the brake caliper bracket. 3. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. Install the brake pads to the caliper bracket. 4. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9821 5. Notice: Refer to Fastener Notice in Service Precautions. Install the lower brake caliper guide pin bolt (1). ^ Tighten the bolt to 34 Nm (25 ft. lbs.). 6. Remove the wheel nuts retaining the brake rotor to the hub. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder auxiliary reservoir to the proper level. 13. Burnish the pads and rotors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9822 Brake Pad: Service and Repair Brake Pads Replacement - Rear Brake Pads Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 9. Remove the C-clamp from the caliper. 10. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2). 11. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9823 brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Without disconnecting the hydraulic brake flexible hose, remove the caliper from the mounting bracket and secure the caliper with heavy mechanics wire, or equivalent. 12. Remove the brake pads from the caliper mounting bracket. 13. Remove the brake pad retainers (1) from the caliper bracket. 14. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 15. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 16. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. 17. Using a spanner wrench type caliper piston installer, fully retract the piston into the caliper bore. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9824 1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 2. Install the brake pad retainers (1) to the brake caliper bracket. 3. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the bottom of the pad when installed in vehicle position. Install the brake pads to the caliper bracket. 4. Remove the support, and install the caliper into position over the disc brake pads and to the caliper mounting bracket. 5. Notice: Refer to Fastener Notice in Service Precautions. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 6. Remove the wheel nuts retaining the brake rotor to the hub. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder auxiliary reservoir to the proper level. 13. Burnish the pads and rotors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 9825 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9830 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9831 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9832 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9833 WARRANTY INFORMATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9834 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9835 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9836 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9837 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9838 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9839 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9840 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9841 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9842 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9843 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9844 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9845 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9846 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9847 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9848 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9849 Brake Align Order Form Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9850 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9851 The list shown is of labor operations for brake service. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 9852 Brake Rotor/Disc: Specifications Front Brakes J41/JM4 Brake Rotor Diameter ...................................................................................... .............................................................................. 256.00 mm (10.079 inch) Brake Rotor Discard Thickness ............................................................................................................................................................. 22.0 mm (0.87 inch) Brake Rotor Maximum Allowable Assembled Lateral Runout ............................................................................................................ 0.06 mm (0.002 inch) Brake Rotor Maximum Allowable Scoring ......................................................................................................................................... 1.50 mm (0.059 inch) Brake Rotor Maximum Allowable Thickness Variation .................................................................................................................... 0.025 mm (0.001 inch) Brake Rotor Minimum Allowable Thickness After Refinish ............................................................................................................. 22.75 mm (0.896 inch) Brake Rotor Thickness - New ............................................................................................................................................................ 23.69 mm (0.933 inch) Front Brakes JL9 Brake Rotor Diameter ........................................................ ............................................................................................................ 296.00 mm (11.653 inch) Brake Rotor Discard Thickness ........................................................................................................................................................... 22.8 mm (0.898 inch) Brake Rotor Maximum Allowable Assembled Lateral Runout ............................................................................................................ 0.06 mm (0.002 inch) Brake Rotor Maximum Allowable Scoring ......................................................................................................................................... 1.50 mm (0.059 inch) Brake Rotor Maximum Allowable Thickness Variation .................................................................................................................... 0.025 mm (0.001 inch) Brake Rotor Minimum Allowable Thickness After Refinish ............................................................................................................... 23.0 mm (0.906 inch) Brake Rotor Thickness - New .............................................................................................................................................................. 26.0 mm (1.023 inch) Rear Brakes JL9 Brake Rotor Diameter ........................................................... ........................................................................................................... 270.0 mm (10.630 inch) Brake Rotor Discard Thickness ........................................................................................................................................................... 11.8 mm (0.465 inch) Brake Rotor Maximum Allowable Assembled Lateral Runout ............................................................................................................ 0.06 mm (0.002 inch) Brake Rotor Maximum Allowable Scoring ......................................................................................................................................... 1.50 mm (0.059 inch) Brake Rotor Maximum Allowable Thickness Variation .................................................................................................................... 0.025 mm (0.001 inch) Brake Rotor Minimum Allowable Thickness After Refinish ............................................................................................................... 12.0 mm (0.472 inch) Brake Rotor Thickness - New .............................................................................................................................................................. 14.0 mm (0.551 inch) All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness specification. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement - Front Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Front Brake Rotor Replacement - Front ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 5. Remove the C-clamp. 6. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Important: Do NOT disconnect the hydraulic brake flexible hose from the caliper. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement - Front > Page 9855 7. Matchmark the position of the brake rotor to the wheel studs. 8. Remove the brake rotor. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 7. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement - Front > Page 9856 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Rear Brake Rotor Replacement - Rear ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 4. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. ^ Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 5. Remove the C-clamp from the caliper. 6. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Important: Do NOT disconnect the hydraulic brake flexible hose from the caliper. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement - Front > Page 9857 7. Matchmark the position of the brake rotor to the wheel studs. 8. Remove the brake rotor. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 7. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement - Front > Page 9858 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing.Do not refinish disc brake rotors in an attempt to correct the following conditions: ^ Brake system noise - squeal, growl, groan ^ Uneven and/or premature disc brake pad wear ^ Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface ^ Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: ^ Thickness variation in excess of the maximum allowable specification ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive blueing discoloration ^ Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Drum Brake Backing Plate Replacement Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the brake shoes. 5. Remove the universal spring (1) from the brake backing plate. 6. Remove the wheel cylinder. 7. Release the rear park brake cable end fitting (1) from the drum brake backing plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 9863 8. Remove the wheel bearing/hub assembly. 9. Remove the brake backing plate. Installation Procedure 1. Install the brake backing plate. 2. Install the wheel bearing/hub assembly. 3. Secure the rear park brake cable end fitting (1) to the brake backing plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 9864 4. Install the wheel cylinder. 5. Install the universal spring (1) to the backing plate. 6. Install the brake shoes. . 7. Adjust the drum brakes. 8. Install the brake drum. 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rotor/Drum Refinishing Labor Operations Brake Drum: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rotor/Drum Refinishing Labor Operations > Page 9869 The list shown is of labor operations for brake service. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 9870 Brake Drum: Specifications Brake Drum Discard Diameter .......................................................................................................................................................... 231.0 mm (9.094 inch) Brake Drum Diameter - New ...................................................................................................................... 230.125 mm ± 0.125 mm (9.06 in ± 0.005 inch) Brake Drum Maximum Allowable Radial Runout ............................................................................................................................. 0.104 mm (0.004 inch) Brake Drum Maximum Allowable Scoring ........................................................................................................................................... 1.5 mm (0.059 inch) Brake Drum Maximum Diameter After Refinish ............................................................................................................................. 230.50 mm (9.075 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement Brake Drum Replacement ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Check to ensure that the park brake is fully released. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the brake drum. 5. If the brake drum is to be reinstalled to the vehicle, use the J 41013 to clean any rust or corrosion from the hub/flange mating surface of the brake drum.If necessary, carefully remove any corrosion from the edge of the drum braking surface in order to ease installation. 6. Use the J 42450-A to clean the wheel hub flange. Installation Procedure 1. Adjust the drum brakes. 2. Install the brake drum. 3. Install the tire and wheel assembly. 4. Apply the brakes approximately three times in order to seat and center the brake shoes within the drum. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 9873 5. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 9874 Brake Drum: Service and Repair Brake Drum Refinishing Brake Drum Refinishing ^ Tools Required J 41013 Rotor/Drum Flange Resurfacing Kit - J 42450-A Hub Cleaning Kit Caution: Refer to Brake Dust Caution in Service Precautions. 1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions: ^ Brake system noise (squeal, growl, groan) ^ Uneven and/or premature brake lining wear ^ Superficial or cosmetic corrosion/rust of the brake drum surface ^ Scoring of the brake drum surface (less than the maximum allowable specification) 2. Brake drums should only be refinished if the following conditions exist: ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive blueing discoloration ^ Scoring of the brake drum surface (in excess of the maximum allowable specification) ^ Radial runout in excess of the maximum allowable specification 3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification: 1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. 2. Inspect each of the brake drums for excessive surface wear and/or radial runout. 4. If the brake drums can be refinished, proceed with the rotor refinishing procedure. 5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange. 6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions. 7. Ensure that any vibration dampening attachments are securely in place. 8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface. 9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe. 10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe. 11. Following the brake lathe manufacturer's instructions, refinish the brake drum. 12. After each successive cut, inspect the brake drum diameter. 13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced. 14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish: 0. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 1. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper. ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper. 2. After applying a non-directional finish, clean each friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner 15. Remove the brake drum from the brake lathe. Important: Failure to clean the corrosion from the wheel bearing flange may result in increased lateral runout of the brake drum and brake system pulsation. 16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake Shoe Lining Minimum Thickness ................................................................................................................................................ 0.5 mm (0.020 inch) Brake Shoe Lining Thickness - New ..................................................................................................................................................... 4.2 mm (0.165 inch) Brake Shoe Lining-to-Drum Clearance .............................................................................................................................................. 0.635 mm (0.025 inch) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9878 Brake Shoe: Adjustments Drum Brake Adjustment ^ Tools Required J 21177-A Drum to Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions. 1. Ensure that the park brake lever is in the fully released position. 2. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer. 3. Pull the boot away from the console to expose the front park brake cable adjusting nut (1). 4. Release the tension from the park brake cable system at the front cable adjusting nut (1).Using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheel assemblies. 7. Remove the brake drums. 8. Position the J 21177-A to widest point of the brake drum inside diameter. 9. Firmly hand tighten the set screw on the J 21177-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9879 10. Remove the J 21177-A from the brake drum and position it over the corresponding brake shoe assembly at its widest point. 11. While holding the J 21177-A in position, insert a 0.635 mm (0.025 inch) feeler gage between one side of the J 21177-A, and the corresponding brake shoe lining. 12. Rotate the brake shoe adjuster screw until the brake shoe linings contact the J 21177-A, and the feeler gage. Brake shoe lining-to-drum clearance: 0.635 mm (0.025 inch) 13. Repeat the above steps for the opposite brake drum and brake shoe assembly. 14. Install the brake drums. 15. Adjust the park brake. 16. Install the rear tire and wheel assemblies. 17. Lower the vehicle. 18. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9880 Brake Shoe: Service and Repair Brake Shoe Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. Remove the adjuster spring (1). Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole. 5. Remove the adjuster actuator lever (1) from the pivot. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9881 6. Using the J 38400 (1), spread the top of the brake shoes apart. 7. Remove the adjuster assembly (2) from the brake shoes. 8. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring while removing the trailing brake shoe. 9. Release the park brake cable from the park brake lever on the trailing shoe. 10. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring while removing the leading brake shoe. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9882 Installation Procedure 1. Measure the brake shoe lining thickness. Brake Shoe Lining Minimum Thickness: 0.5 mm (0.020 inch). 2. If the brake shoe lining thickness is at or below the minimum specification, replace the brake shoes. 3. Apply a thin, light coat of high temperature silicone brake lubricant to the brake shoe contact surfaces of the brake backing plate. 4. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out while installing the leading brake shoe. Ensure that the universal spring engages the brake shoe web hole. 5. Install the park brake cable to the park brake lever on the trailing brake shoe. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9883 6. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out while installing the trailing brake shoe. Ensure that the universal spring properly engages the brake shoe web hole. 7. Using the J 38400 (1), spread the top of the brake shoes apart. 8. Install the adjuster assembly (2) to the brake shoes. 9. Install the adjuster actuator lever (1) to the brake shoe and the adjuster assembly. Ensure that the lever is properly engaged between the adjuster assembly and the brake shoe. 10. Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9884 Install the adjuster spring (1). Ensure that the loop end of the spring fully engages the tab on the actuator lever. 11. Adjust the drum brakes. 12. Install the brake drum. 13. Install the tire and wheel assembly. 14. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 9889 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Clean any debris and contaminants from around the wheel cylinder. 5. Remove the wheel cylinder bleeder cap and valve (2). 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and contamination. 7. Remove the wheel cylinder mounting bolts (3). 8. Using the J 38400, spread the top of the brakes shoes apart, then remove the wheel cylinder from the brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 9890 1. Using the J 38400, spread the top of the brakes shoes apart, then install the wheel cylinder to the brake backing plate. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel cylinder mounting bolts (3). ^ Tighten the bolts to 16 Nm (12 ft. lbs.). 3. Remove the cap from the brake pipe end. 4. Connect the brake pipe fitting (1) at the wheel cylinder. ^ Tighten the fitting to 19 Nm (14 ft. lbs.). 5. Install the wheel cylinder bleeder valve. ^ Tighten the valve to 8 Nm (71 inch lbs.). 6. Install the brake drum. 7. Bleed the hydraulic brake system. 8. Install the bleeder valve cap. 9. Adjust the drum brakes. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base brake system. The automated bleed procedure is recommended when one of the following conditions exist: ^ Base brake system bleeding does not achieve the desired pedal height or feel ^ Extreme loss of brake fluid has occurred ^ Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure 1. Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. Raise and support the vehicle. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. 10. Following the directions given on the scan tool, pressure bleed the base brake system. 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle, and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. 17. Inspect the brake fluid level. 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9896 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 21. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9897 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice; When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component.For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4. Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has been purged from the first port of the component that was bled, loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has been bled. 10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings is properly tightened. 4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532, or equivalent, to the J 44894-A. 7. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 8. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks.Any brake fluid leaks identified require repair prior to completing this procedure. 10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves is properly tightened. 20. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 44894-A. 21. Remove the J 44894-A from the brake master cylinder reservoir. 22. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9898 2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). 24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 25. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 9899 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir, if bleeding from a manual transmission vehicle ensure to cap or plug the clutch hose port while bleeding the master cylinder. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9904 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (1). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the brake caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper guide pin bolts (1). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9905 3. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 4. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9906 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9907 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). 8. Important: Do not use abrasives to clean the brake caliper piston. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal (4) with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9908 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the bleeder valve to the caliper. ^ Tighten the brake bleeder valve to 11 Nm (97 inch lbs.). 10. Install the bleeder valve cap. 11. Install the brake caliper to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9909 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 5. Release the tension from the park brake cables.With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the tire and wheel assembly. 8. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 9. Release the park brake cable end (1) from the lever on the caliper. 10. Release the retaining tabs (4) securing the park brake cable to the bracket on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9910 11. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 12. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 13. Remove the C-clamp from the caliper. 14. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 15. Remove the brake hose (3) from the brake caliper. 16. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 17. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 18. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9911 19. Remove the brake caliper from the caliper bracket. 20. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 21. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4). 4. Secure the park brake cable end (1) to the lever on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9912 5. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 6. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Remove the wheel nuts retaining the brake rotor to the wheel hub. 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Adjust the park brake cable tension. 16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9913 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the rear brake caliper from vehicle. 2. Important: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and into the non-serviceable integral park brake mechanism. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9914 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism: Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. 9. Important: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. If the integral park brake mechanism was not operating properly, binding or seized, replace the brake caliper assembly. 10. Important: Do not use abrasives to clean the brake caliper piston. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 13. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 14. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. 15. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 16. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9915 3. Install the new dust boot seal onto the caliper piston (2). 4. Insert the caliper piston into the caliper bore. Using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). 5. Fully seat the piston dust boot seal in the seal counterbore. 6. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 7. Install the brake caliper to the vehicle. Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9916 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9917 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (1). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the brake caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper guide pin bolts (1). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9918 3. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 4. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9919 pistons are blown out, even with the padding provided, it may be damaged. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). 8. Important: Do not use abrasives to clean the brake caliper piston. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9920 1. Lubricate the new piston seal (4) with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the bleeder valve to the caliper. ^ Tighten the brake bleeder valve to 11 Nm (97 inch lbs.). 10. Install the bleeder valve cap. 11. Install the brake caliper to the vehicle. Brake Caliper Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9921 Brake Caliper Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 5. Release the tension from the park brake cables.With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the tire and wheel assembly. 8. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 9. Release the park brake cable end (1) from the lever on the caliper. 10. Release the retaining tabs (4) securing the park brake cable to the bracket on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9922 11. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 12. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 inch) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 inch) of travel only. 13. Remove the C-clamp from the caliper. 14. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 15. Remove the brake hose (3) from the brake caliper. 16. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 17. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 18. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9923 19. Remove the brake caliper from the caliper bracket. 20. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 21. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper to the caliper bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4). 4. Secure the park brake cable end (1) to the lever on the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9924 5. Remove the caps or plugs from the brake caliper opening and the brake hose (3). 6. Important: Do not reuse the copper brake hose gaskets. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Remove the wheel nuts retaining the brake rotor to the wheel hub. 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Adjust the park brake cable tension. 16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the rear brake caliper from vehicle. 2. Important: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9925 into the non-serviceable integral park brake mechanism. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism: Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. 9. Important: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. If the integral park brake mechanism was not operating properly, binding or seized, replace the brake caliper assembly. 10. Important: Do not use abrasives to clean the brake caliper piston. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 12. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 13. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 14. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9926 15. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 16. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the new dust boot seal onto the caliper piston (2). 4. Insert the caliper piston into the caliper bore. Using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9927 5. Fully seat the piston dust boot seal in the seal counterbore. 6. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 7. Install the brake caliper to the vehicle. Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (2), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9928 2. Remove the brake pads from the brake caliper bracket. 3. Remove the brake pad retainers (1) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 5. Inspect the disc brake pad retainers (1) for the following: ^ Bent mounting tabs ^ Excessive corrosion ^ Looseness at the brake caliper mounting bracket ^ Looseness at the disc brake pads 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the steering knuckle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9929 9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (5). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Install the brake caliper mounting bracket to the steering knuckle. 2. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts (1). ^ Tighten the bolts to 115 Nm (85 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9930 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 4. Clean the brake pad mating surfaces of the brake pad retainers (1). 5. Install the brake pad retainers (1) to the brake caliper bracket. 6. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. Install the brake pads to the brake caliper bracket. 7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads from the brake caliper bracket. 3. Remove the brake pad retainers (1) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion. 5. Inspect the disc brake pad retainers (1) for the following: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9931 ^ Bent mounting tabs ^ Excessive corrosion ^ Looseness at the brake caliper mounting bracket ^ Looseness at the disc brake pads 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the rear axle. 9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: ^ Restricted caliper guide pin movement ^ Looseness in the brake caliper mounting bracket ^ Seized or binding caliper guide pins ^ Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 9932 1. Install the brake caliper mounting bracket to the rear axle. 2. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts (1). ^ Tighten the bolts to 115 Nm (85 ft. lbs.). 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only. 4. Clean the brake pad mating surfaces of the brake pad retainers (1). 5. Install the brake pad retainers (1) to the brake caliper bracket. 6. Important: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the bottom of the pad when installed in vehicle position. Install the brake pads to the brake caliper bracket. 7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not provided by the vehicle manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 9937 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LR of the Engine Compartment LR of the Engine Compartment 1 - Brake Fluid Level Switch 2 - Windshield Wiper Motor 3 - LF Strut Tower 4 - Fuse Block Underhood Connectors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 9941 Brake Fluid Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement ^ Tools Required J 45405 Brake Pipe Flaring Kit Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: When servicing the brake pipes, note the following: ^ If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. ^ Use fittings of the appropriate size and type. ^ Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. ^ Allow adequate clearance in order to maneuver the J 45405. ^ Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. ^ 6.35 mm (0.250 inch) for 4.76 mm (3/16 inch) diameter pipe ^ 9.50 mm (0.374 inch) for 6.35 mm (1/4 inch) diameter pipe Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405, carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9946 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. 1. Select the appropriate blade on the coating stripping tool included in the J 45405, by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. ^ 6.35 mm (0.250 inch) blade for 4.76 mm (3/16 inch) diameter pipe ^ 9.50 mm (0.374 inch) blade for 6.35 mm (1/4 inch) diameter pipe 2. Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. 3. While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the metal surface of the brake pipe. 4. Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. 5. After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. 6. Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. 7. Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. ^ 6.35 mm (0.250 inch) for 4.76 mm (3/16 inch) diameter pipe ^ 9.50 mm (0.374 inch) for 6.35 mm (1/4 inch) diameter pipe 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405. 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9947 13. Loosen the die clamping screw of the J 45405. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9948 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9949 32. Inspect the brake pipe flare for correct shape and diameter (a). ^ 6.92 mm (0.272 inch) within 0.18 mm (0.007 inch) flare diameter for 4.76 mm (3/16 inch) diameter pipe ^ 8.92 mm (0.351 inch) within 0.18 mm (0.007 inch) flare diameter for 6.35 mm (1/4 inch) diameter pipe 33. Important: When installing the pipe, maintain a clearance of 19 mm (3/4 inch) from all moving or vibrating components. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9950 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9951 Brake Hose Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9952 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Caliper) Brake Hose Replacement - Rear (Caliper) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose ends and brake pipe fitting. 4. Using a backup wrench on the hose fitting (2), disconnect the brake pipe fitting (1) from the brake hose. Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination. 5. Remove the brake hose retaining clip (3) from the hose mounting bracket. 6. Remove the hose from the mounting bracket. 7. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 8. Remove the brake hose (3) from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end. 10. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9953 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. 2. Important: Install NEW copper brake hose gaskets (2). Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). 3. Notice: Install the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 48 Nm (35 ft. lbs.). 4. Install the brake hose to the brake hose mounting bracket. Align the hose fitting with the notch in the bracket. 5. Install the hose retaining clip (3) onto the hose fitting at the hose bracket. 6. Using a backup wrench on the hose fitting, connect the brake pipe fitting at the rear brake hose. ^ Tighten the fitting to 19 Nm (14 ft. lbs.). 7. Install the tire and wheel assembly. 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9954 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Jounce) Brake Hose Replacement - Rear (Jounce) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose ends and brake pipe fittings. 4. Using a backup wrench on the hose fitting, disconnect the brake pipe fittings from the brake hose. Cap or plug the brake pipe fitting ends and the brake hose ends to prevent fluid loss and contamination. 5. Remove the brake hose retaining clips (1) from the hose mounting brackets. 6. Remove the hose from the mounting brackets. Installation Procedure 1. Install the brake hose to the brake hose mounting brackets. Align the hose fittings with the notch in the brackets. 2. Install the hose retaining clips (1) onto the hose fittings at the hose brackets. 3. Notice: Using a backup wrench on the hose fitting, connect the brake pipe fittings at the rear brake hose. ^ Tighten the fittings to 19 Nm (14 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9955 4. Install the tire and wheel assembly. 5. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 6. Bleed the hydraulic brake system. 7. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Page 9959 Proportioning Valve Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9964 Brake Pressure Modulator Valve (BPMV) Bracket Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9965 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9966 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 9967 Brake Pressure Modulator Valve (BPMV) Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Auto Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9972 Master Cylinder Replacement (Auto Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9973 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Manual Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9974 Master Cylinder Replacement (Manual Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9975 Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir, if bleeding from a manual transmission vehicle ensure to cap or plug the clutch hose port while bleeding the master cylinder. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9976 Brake Master Cylinder: Service and Repair Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9977 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Auto Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9978 Master Cylinder Replacement (Auto Transmission) Master Cylinder Replacement (Manual Transmission) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9979 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9980 Master Cylinder Replacement (Manual Transmission) Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9981 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir, if bleeding from a manual transmission vehicle ensure to cap or plug the clutch hose port while bleeding the master cylinder. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Fluid Level Sensor Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9982 Master Cylinder Fluid Level Sensor Replacement Master Cylinder Reservoir Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9983 Master Cylinder Reservoir Replacement Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Auto Transmission) > Page 9984 Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder auxiliary reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 9989 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Clean any debris and contaminants from around the wheel cylinder. 5. Remove the wheel cylinder bleeder cap and valve (2). 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and contamination. 7. Remove the wheel cylinder mounting bolts (3). 8. Using the J 38400, spread the top of the brakes shoes apart, then remove the wheel cylinder from the brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 9990 1. Using the J 38400, spread the top of the brakes shoes apart, then install the wheel cylinder to the brake backing plate. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel cylinder mounting bolts (3). ^ Tighten the bolts to 16 Nm (12 ft. lbs.). 3. Remove the cap from the brake pipe end. 4. Connect the brake pipe fitting (1) at the wheel cylinder. ^ Tighten the fitting to 19 Nm (14 ft. lbs.). 5. Install the wheel cylinder bleeder valve. ^ Tighten the valve to 8 Nm (71 inch lbs.). 6. Install the brake drum. 7. Bleed the hydraulic brake system. 8. Install the bleeder valve cap. 9. Adjust the drum brakes. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Park Brake Adjustment (Disc) Parking Brake Cable: Adjustments Park Brake Adjustment (Disc) Park Brake Adjustment (Disc) Caution: Refer to Brake Dust Caution in Service Precautions. Important: The park brake cable adjusting nut is a nylon lock type. Use ONLY HAND TOOLS whenever tightening or loosening the adjusting nut. 1. Apply and fully release the park brake several times. Verify that the park brake lever releases completely. 2. Turn ON the ignition. Verify the red BRAKE warning lamp is not illuminated. 3. If the red BRAKE warning lamp is illuminated, verify the following: ^ The park brake lever is in the fully released position and against the stop. ^ There is no slack in the park brake cables. 4. If the red BRAKE warning lamp remained illuminated and there were no other visible causes, refer to Symptoms - Hydraulic Brakes in Hydraulic Brakes. 5. Turn OFF the ignition. 6. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 7. With the park brake lever in the released position, loosen the adjusting nut (1) enough to completely relieve tension on the front cable. 8. Raise and support the vehicle. Raise the vehicle just enough to observe the rear calipers and rotate the rear tire and wheel assemblies. 9. With all tension relieved from the park brake cables, rotate the rear tire and wheel assemblies, or the rear brake rotors if the wheels have been removed. Observe the amount of effort required for rotation, and the amount of drag if present. 10. Tighten the park brake cable adjusting nut (1) until all slack is taken out of the front cable. 11. Further tighten the adjusting nut (1) until one of the park brake levers on the rear calipers is just lifted off the stop on the caliper housing. 12. Slowly back off the adjusting nut until the park brake lever just rests on the stop. 13. Back off the adjusting nut one full turn. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Park Brake Adjustment (Disc) > Page 9996 14. Fully apply and release the park brake lever 3-5 times. 15. Raise the park brake lever 3 detent positions and attempt to rotate the rear tire and wheel assemblies, or the rear brake rotors. ^ If rotating the tire and wheel assemblies, they should be difficult to rotate, but should not be locked. ^ If rotating the brake rotors, they should be locked. 16. Raise the park brake lever one additional detent position and attempt to rotate the rear tire and wheel assemblies, or the rear brake rotors. The tire and wheel assemblies, or the rear brake rotors should be locked. 17. Fully release the park brake lever. 18. Verify the park brake is released by rotating the rear tire and wheel assemblies, or the rear brake rotors. The rotors should rotate freely and exhibit no brake shoe drag from the park brake system. 19. With the lever released, if the rotors required more effort to rotate, or exhibited more drag than noted previously when all cable tension was relieved, check the park brake levers on the rear calipers. The levers should be on the stops. 20. If the levers are not against the stops, loosen the adjusting nut just until the levers rest against the stops, then repeat steps 14-18. 21. If the rotors still do not rotate freely, with the park lever fully released, park brake adjustment is not the cause of any drag in the brake system. 22. Lower the vehicle. 23. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. 24. Release the park brake lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Park Brake Adjustment (Disc) > Page 9997 Parking Brake Cable: Adjustments Park Brake Adjustment (Drum) Park Brake Adjustment (Drum) Caution: Refer to Brake Dust Caution in Service Precautions. Important: The park brake cable adjusting nut is a nylon lock type. Use ONLY HAND TOOLS whenever tightening or loosening the adjusting nut. 1. Apply and fully release the park brake several times. Verify that the park brake lever releases completely. 2. Turn ON the ignition. Verify the red BRAKE warning lamp is not illuminated. 3. If the red BRAKE warning lamp is illuminated, verify the following: ^ The park brake lever is in the fully released position and against the stop. ^ There is no slack in the park brake cables. 4. If the red BRAKE warning lamp remained illuminated and there were no other visible causes, refer to Symptoms - Hydraulic Brakes in Hydraulic Brakes. 5. Turn OFF the ignition. 6. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back. 7. With the park brake lever in the released position, loosen the adjusting nut (1) enough to completely relieve tension on the front cable. 8. Raise and support the vehicle. Raise the vehicle just enough to allow rear tire and wheel assembly removal and rear drum adjustment. 9. Remove the rear tire and wheel assemblies. 10. Adjust the rear drum brakes. 11. Ensure there is no brake shoe drag after adjustment by rotating the brake drums. If drag exists, re-center the brake shoes and perform the brake shoe adjustment again. 12. Install 2 wheel nuts to the wheel studs and firmly hand tighten in order to retain the brake drums. 13. Raise the park brake lever 6 detent positions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Park Brake Adjustment (Disc) > Page 9998 14. Notice: Refer to Fastener Notice in Service Precautions. Tighten the park brake cable adjusting nut (1). ^ Tighten the nut to 3.9 Nm (35 inch lbs.). 15. Attempt to rotate the rear brake drums. There should be no rotation forward or rearward. 16. Fully release the park brake lever. 17. Verify the park brake is released by rotating the rear brake drums. The drums should rotate freely and exhibit no brake shoe drag. 18. If the drums do not rotate freely, repeat the park brake cable adjustment procedure. 19. Raise the park brake lever 3 detent positions and attempt to rotate the rear brake drums: ^ One of the brake drums should not rotate forward or rearward. ^ The other brake drum should not rotate forward or rearward, or should require substantial effort to rotate. 20. Raise the park brake lever one additional detent position and attempt to rotate the rear brake drums. 21. Verify that the left and right brake drums cannot be rotated. 22. Remove the wheel nuts retaining the brake drums. 23. Install the rear tire and wheel assemblies. 24. Lower the vehicle. 25. Position the park brake lever boot to the floor console and press the boot retainer into place to secure. 26. Release the park brake lever. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Remove the front floor console storage compartment. 2. With park brake lever in the released position, using ONLY HAND TOOLS, remove the park brake cable adjusting nut and washer. 3. Release the rear park brake cable ends from the cable equalizer on the front cable. 4. Remove the front park brake cable from the park brake lever by pulling the cable rearward. Installation Procedure 1. Install the front park brake cable to the park brake lever. 2. Install the rear cable ends to the cable equalizer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10001 3. Using ONLY HAND TOOLS, install the washer and NEW adjusting nut (1) to the front park brake cable. 4. Adjust the park brake cable tension. 5. Install the front floor console storage compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10002 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Rear (Disc) Park Brake Cable Replacement - Rear (Disc) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the front floor console. 2. Ensure that the park brake lever is in the fully released position. 3. Release the tension from the park brake cables.Using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 4. Remove the rear seat lower cushion. 5. Remove the rear carpet retainers. 6. Position the carpet forward in order to access the rear park brake cables and body pass-thru grommets. 7. With the park brake lever in the released position, release the appropriate rear park brake cable end (3) from the cable equalizer. 8. Release the rear cable fitting (2) from the park brake lever bracket (1) and remove the cable from the lever assembly. 9. Release the rear park brake cable body pass-thru grommet. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10003 10. Raise and support the vehicle. 11. If the park brake cable is being reused, release the tab on the underbody retainer (2) and remove the park brake cable from the retainer. 12. If a new park brake cable will be installed, release the underbody retainer (2) from the vehicle underbody. 13. Important: Do NOT pull on the park brake cable to release the C-shaped retainer (1) on the cable from the bracket at the rear axle trailing arm pivot. Using a suitable tool, carefully pry against the edge of the C-shaped retainer (1) on the park brake cable, to release the retainer from the bracket at the rear axle trailing arm pivot. 14. Remove the cable from the opening in the vehicle underbody. 15. Remove the rear tire and wheel assembly. 16. Release the park brake cable end (1) from the caliper park brake lever. 17. Using a flat-bladed screwdriver, depress the retaining tabs (4) on the park brake cable fitting, and release the cable fitting from the cable bracket. 18. Remove the park brake cable guide (3) retaining bolt (2), and remove the cable. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10004 1. Insert the park brake cable through the cable bracket on the caliper. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable guide (3) retaining bolt (2). ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. Secure the cable fitting to the cable bracket. Ensure that the retaining tabs (4) are fully seated. 4. Install the cable end (1) to the caliper park brake lever. 5. Install the rear tire and wheel assembly. 6. Insert the cable through the opening in the vehicle underbody. 7. Install the C-shaped retainer (1) on the park brake cable into the bracket at the rear axle trailing arm pivot. 8. Install and secure park brake cable pass-thru grommet (3) to the opening in the vehicle underbody. 9. If a new park brake cable is being installed, secure the underbody retainer (2) to the vehicle underbody. 10. If the park brake cable is being reused, install the park brake cable to the underbody retainer (2) and press the tab into place to secure. 11. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10005 12. Secure the cable fitting (2) to the park brake lever bracket (1). Attempt to pull the park brake cable free of the lever bracket, to ensure that the retaining tabs on the fitting are properly secured. 13. Install the cable end (3) to the cable equalizer. 14. Reposition the carpet to the installed position. 15. Install the rear carpet retainers. 16. Install the rear seat lower cushion. 17. Adjust the park brake cable tension. 18. Install the front floor console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10006 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Rear (Drum) Park Brake Cable Replacement - Rear (Drum) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Remove the front floor console. 2. Ensure that the park brake lever is in the fully released position. 3. Release the tension from the park brake cables.Using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 4. Remove the rear seat lower cushion. 5. Remove the rear carpet retainers. 6. Position the carpet forward in order to access the rear park brake cables and body pass-thru grommets. 7. With the park brake lever in the released position, release the appropriate rear park brake cable end (3) from the cable equalizer. 8. Release the rear cable fitting (2) from the park brake lever bracket (1) and remove the cable from the lever assembly. 9. Release the rear park brake cable body pass-thru grommet. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10007 10. Raise and support the vehicle. 11. If the park brake cable is being reused, release the tab on the underbody retainer (2) and remove the park brake cable from the retainer. 12. If a new park brake cable will be installed, release the underbody retainer (2) from the vehicle underbody. 13. Important: Do NOT pull on the park brake cable to release the C-shaped retainer (1) on the cable from the bracket at the rear axle trailing arm pivot. Using a suitable tool, carefully pry against the edge of the C-shaped retainer (1) on the park brake cable, to release the retainer from the bracket at the rear axle trailing arm pivot. 14. Remove the cable from the opening in the vehicle underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10008 15. Remove the rear tire and wheel assembly. 16. Remove the brake drum. 17. Using a flat-bladed screwdriver, depress the visible retaining tab (1) on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. 18. Rotate the park brake cable to expose the other retaining tab. 19. Using a flat-bladed screwdriver, depress the remaining retaining tab on the park brake cable fitting, and release the cable fitting from the backing plate. 20. Move the majority of the cable return spring back through the opening in the backing plate. 21. Push the cable toward the rear of the vehicle, just enough to clear the cable end from the slot on the park brake lever. 22. Using a flat-bladed screwdriver, lift the cable to fully release the cable from the lever, then remove the cable. Installation Procedure 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the cable toward the rear of the vehicle, along the outside of the trailing brake shoe, until the cable end is positioned just past the slot on the park brake lever. 3. While holding the cable in position from front to rear, move the cable end to the back of the park brake lever. 4. Press the cable down into the slot on the lever, then pull the cable toward the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Adjust the rear drum brakes. 9. Install the brake drum. 10. Install the rear tire and wheel assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10009 11. Insert the cable through the opening in the vehicle underbody. 12. Install the C-shaped retainer (1) on the park brake cable into the bracket at the rear axle trailing arm pivot. 13. Install and secure park brake cable pass-thru grommet (1) to the opening in the vehicle underbody. 14. If a new park brake cable is being installed, secure the underbody retainer (2) to the vehicle underbody. 15. If the park brake cable is being reused, install the park brake cable to the underbody retainer (2) and press the tab into place to secure. 16. Lower the vehicle. 17. Secure the cable fitting (2) to the park brake lever bracket (1). Attempt to pull the park brake cable free of the lever bracket, to ensure that the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 10010 retaining tabs on the fitting are properly secured. 18. Install the cable end (3) to the cable equalizer. 19. Reposition the carpet to the installed position. 20. Install the rear carpet retainers. 21. Install the rear seat lower cushion. 22. Adjust the park brake cable tension. 23. Install the front floor console. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Park Brake Lever Assembly Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the front floor console. 3. Ensure that the park brake lever is in the fully released position. 4. Release the tension from the park brake cable system at the front cable adjusting nut (1).Using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod. 5. Disconnect the electrical connector (1) from the park brake warning lamp switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 10014 6. With the park brake lever in the released position, release the rear park brake cable ends (3) from the cable equalizer. 7. Release the rear cable fittings (2) from the park brake lever bracket (1). 8. Remove the park brake lever mounting nuts. 9. Remove the park brake lever assembly from the vehicle. Installation Procedure 1. Install the park brake lever assembly to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 10015 2. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the park brake lever assembly mounting nuts in the sequence shown. Install the park brake lever assembly mounting nuts. ^ Tighten the nuts in sequence to 25 Nm (18 ft. lbs.). 3. Secure the rear cable fittings (2) to the park brake lever bracket (1). Attempt to pull the park brake cables free of the lever bracket, to ensure that the retaining tabs on the fittings are properly secured. 4. Install the cable ends (3) to the cable equalizer. 5. Connect the electrical connector (1) to the park brake warning lamp switch. 6. Adjust the park brake cable tension. 7. Install the front floor console. 8. Enable the SIR system. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 10019 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 10020 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair Vacuum Brake Booster: Service and Repair Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 10025 Vacuum Brake Booster Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement (2.0L) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10038 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10039 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Electronic Brake Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10045 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10046 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 10052 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 10058 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 10059 Electronic Brake Control Module: Locations ABS Component Views 1 - Transmission Control Module (TCM) (MN5) 2 - LF Strut Tower 3 - Engine Control Module (ECM) (L61) 4 - Electronic Brake Control Module (EBCM) (JM4/JL9) 5 - Fuse Block - Underhood Bracket Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 10060 Electronic Brake Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 10061 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 10062 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. If equipped with RPO LSJ, remove the throttle body air snorkel. 3. Clean the electronic brake control module (EBCM) (3) to brake pressure modulator valve (BPMV) (4) area of any accumulated dirt and foreign material. 4. Disconnect the electrical connector (1) from the EBCM (3). 5. Remove the 4 EBCM-to-BPMV retaining bolts (2). 6. Important: Do Not use a metal tool to pry the EBCM from the BPMV. Use care to ensure that the EBCM-to-BPMV mating surfaces are not scratched during EBCM removal. Separate the EBCM (3) from the BPMV (4) by carefully pulling apart. Installation Procedure 1. Clean the EBCM mating surface of the BPMV (4), with denatured alcohol, or equivalent. 2. Ensure that the EBCM (3) to BPMV (4) seal is fully seated in the groove on the EBCM (3). 3. Install the EBCM (3) to the BPMV (4). Use care when aligning the EBCM (3) to the BPMV electrical terminals (4). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 EBCM-to-BPMV retaining bolts (2). Tighten the bolts in a criss-cross pattern. ^ Tighten the bolts to 4.5 Nm (40 inch lbs.). 5. Connect the electrical connector (1) to the EBCM (3). 6. If equipped with RPO LSJ, install the throttle body air snorkel. 7. If a new EBCM was installed, the EBCM must be programmed. 8. Turn the ignition switch to the ON position. DO NOT start engine. 9. Perform the Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: Customer Interest M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10071 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10072 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping Traction Control Module: All Technical Service Bulletins M/T - Fluid Leaks/Clutch Slipping TECHNICAL Bulletin No.: 09-07-29-003 Date: June 12, 2009 Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval) Models: 2005-2009 Chevrolet Cobalt SS 2008-2009 Chevrolet HHR SS 2004-2007 Saturn ION Redline Equipped with 5-Speed Manual Transmission (RPO MU3) Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos) Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted. Condition Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing. Cause This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10078 Correction Important Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval. For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts. For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires): - Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area. - Inspect the upper right side mount for fluid leaks or (rubber) structural failure. - Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts). Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2(R) is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI. Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286) 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 2. Remove the cover from the underhood electrical center. 3. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. Note Rotate the hose to stop brake fluid from running out of it. 4. Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1). 5. Install the clutch actuator pipe elbow assembly, GM P/N 24252286. 6. Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2). 7. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding. 8. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > 09-07-29-003 > Jun > 09 > M/T - Fluid Leaks/Clutch Slipping > Page 10079 Parts Information Warranty Information Use labor operation and time that is approved by the District Service Manager/Warranty Manager. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LR of the Engine Compartment LR of the Engine Compartment 1 - Brake Fluid Level Switch 2 - Windshield Wiper Motor 3 - LF Strut Tower 4 - Fuse Block Underhood Connectors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 10084 Brake Fluid Level Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 10088 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 10089 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensors (JM4/JL9) Wheel Speed Sensors (JM4/JL9) 1 - Wheel Speed Sensor (WSS) - LF 2 - Wheel Speed Sensor (WSS) - RF 3 - Wheel Speed Sensor (WSS) - RR 4 - Wheel Speed Sensor (WSS) - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 10093 Wheel Speed Sensor: Diagrams Wheel Speed Sensor - LF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 10094 Wheel Speed Sensor - RF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 10095 Wheel Speed Sensor - LR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 10096 Wheel Speed Sensor - RR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 10102 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 10103 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 10112 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 10118 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Technical Service Bulletins > Page 10119 Clutch Switch: Locations Manual Transmission Component Views Pedal Components Pedal Components 1 - Clutch Pedal Position (CCP) Switch (M86) 2 - Clutch Start Switch (M86) 3 - Stop Lamp Switch 4 - Cruise Control Cancel Switch (M86) 5 - Accelerator Pedal Position (APP) Sensor 6 - Floor Pan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 Clutch Switch: Diagrams M86 Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 > Page 10122 Clutch Start Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > M86 > Page 10123 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Old Pedal Clutch Switch: Adjustments Old Pedal Clutch Pedal Position Switch Adjustment (Old Pedal) Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Remove the CPP switch (1) from the clutch pedal by twisting the CPP switch (1) counterclockwise. Installation Procedure 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly and twist the CPP switch (1) clockwise to seat. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Remove the drill bit. 5. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Old Pedal > Page 10126 Clutch Switch: Adjustments New Pedal Clutch Pedal Position Switch Adjustment (New Pedal) Installation Procedure 1. While holding the pedal in the fully released position, press the switch (2) toward the pedal until the barrel of the switch (2) touches the shipping clip (1). 2. Remove the shipping clip (1). 3. Connect the electrical connector (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Page 10127 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Rotate the CPP switch (1) counterclockwise to release, and remove the switch from the clutch pedal assembly. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Adjustments > Page 10128 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Rotate the switch (1) clockwise to secure. 5. Remove the drill bit. 6. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10142 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10143 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10144 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 10153 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10163 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10164 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10165 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 10174 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: - Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 10188 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery.Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery.Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery.This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure Negative: Service and Repair Disconnect/Connect Procedure BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE REMOVAL PROCEDURE 1. Record all of the vehicle preset radio stations. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. - Refer to SIR Caution in Service Precaution. 2. Turn OFF all the lamps and the accessories. 3. Make sure the ignition switch is in the OFF position. 4. Disconnect the battery negative cable from the battery (2). INSTALLATION PROCEDURE 1. Connect the battery negative cable to the battery (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 15 N.m (11 lb ft). IMPORTANT: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure > Page 10194 2. Reset the radio stations and the clock. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure > Page 10195 Negative: Service and Repair Replacement procedure BATTERY NEGATIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable (1) from the negative battery post. 2. Remove the negative battery cable bolt (2). 3. Disconnect the sensor connection (3). 4. Remove the ground cable from the vehicle, noting the routing for installation. INSTALLATION PROCEDURE 1. Connect the sensor (3). 2. Install the negative battery cable bolt (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolt to 20 N.m (15 lb ft). 3. Connect the negative battery cable (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information Positive: Technician Safety Information CAUTION: - Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information > Page 10200 Positive: Vehicle Damage Warnings BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) Positive: Service and Repair Replacement Procedure (Underhood Junction Block to Starter) BATTERY POSITIVE CABLE REPLACEMENT (UNDERHOOD JUNCTION BLOCK TO STARTER) REMOVAL PROCEDURE 1. Disconnect the negative battery cable from the battery. IMPORTANT: Always use replacement cables that are of the same type, diameter and length of the cables that you are replacing. - Always route the replacement cable the same way as the original. 2. Disconnect the positive battery cable nut (1) from the underhood junction block terminal. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the positive battery cable nut (2). 5. Disconnect the positive battery cable (1) from the starter. 6. Remove the positive battery cable from the vehicle. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10203 1. Place the battery cable in the vehicle using the original routing. 2. Connect the positive battery cable (1) to the starter and the positive cable nut (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the starter terminal nut to 17 N.m (13 lb ft). 3. Tape the positive battery cable to the negative battery cable near the transmission. 4. Lower the vehicle. 5. Connect the positive cable (2) to the underhood junction block. 6. Connect the positive battery cable nut (1) to the underhood junction block. Tighten the bolt (2) to 17 N.m (13 lb ft). 7. Connect the negative battery cable to the battery. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10204 Positive: Service and Repair Replacement Procedure (Battery to Underhood Junction Block) BATTERY POSITIVE CABLE REPLACEMENT (BATTERY TO UNDERHOOD JUNCTION BLOCK) REMOVAL PROCEDURE 1. Disconnect the negative battery cable from the battery. IMPORTANT: Always use replacement cables that are of the same type, diameter and length of the cables that you are replacing. - Always route the replacement cable the same way as the original cable. 2. Disconnect the positive battery cable end (1) from the battery. 3. Disconnect the positive battery cable (3) from the connector (2). 4. Remove the underhood junction block. 5. Unseat the cable retainer from the underhood area near the LT shock tower. 6. Remove the rear seat cushion. 7. Remove the drivers seat assembly. 8. Pull back the carpet and sound insulation padding in order to expose the battery positive cable. Refer to Carpet Replacement in Interior Trim. 9. Remove the battery cable clip (1) from the weld studs. 10. Remove the battery cable clip (2) from the floor plan. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10205 11. Release all of the cable hold down clips (1) in the interior area of the floor pan. 12. Remove the battery cable from the body harness clips (1). 13. Remove the battery positive cable nut (1). 14. Remove the battery cable (2) from the junction block stud. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10206 15. Remove the battery cable from the remaining body harness clips (2). 16. Pull the interior to engine compartment grommet (1) from the interior in order to release the battery cable from the vehicle. INSTALLATION PROCEDURE 1. Route the battery cable through the engine compartment pass through and up to the underhood junction. 2. Seat the interior to engine compartment grommet (1) by pulling from the engine compartment side of the battery cable. 3. Install the battery cable to the retaining clips (2). 4. Install the battery cable (2) to the junction block stud. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10207 5. Install the battery cable nut (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 15 N.m (11 lb ft). 6. Install the battery cable to the body harness clips (1). 7. Route the battery cable along the floor pan and install the battery cable to all of the hold down clips (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure (Underhood Junction Block to Starter) > Page 10208 8. Install the battery cable clip (2) to the floor pan. 9. Install the battery cable clips (1) to the floor pan studs. 10. Position the sound insulation and carpet to the interior. Refer to Carpet Replacement in Interior Trim. 11. Install the drivers seat assembly. 12. Install the rear seat cushion. 13. Secure the cable retainer to the underhood area near the LT shock tower. 14. Install the underhood junction block. 15. Connect the positive battery cable end (1) to the battery. Tighten the positive battery terminal bolt (1) to 15 N.m (11 lb ft). 16. Connect the positive cable (3) to the connector (2). 17. Connect the negative battery cable (1) to the battery. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 10212 Battery Current Sensor: Service and Repair BATTERY CURRENT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery current sensor electrical connector (2). 2. Remove the battery negative cable from the vehicle. 3. Remove the tape (3) securing the battery current sensor (1) to the negative battery cable (4). 4. Remove the battery current sensor (2) from the ground end of the negative battery cable (1). INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 10213 1. Install the battery current sensor (2) by passing the ground end of the negative battery cable (1) through the sensor. Slide the current sensor to the battery end of the cable in order to encompass all ground wires attached to battery. 2. Wrap electrical tape (3) around the battery current sensor (1) in order to secure the battery current sensor to the negative battery cable (4). IMPORTANT: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. Also ensure that ALL grounding wires connected to negative post of battery pass through the sensor. 3. Install the battery negative cable to the vehicle. 4. Connect the battery current sensor electrical connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair Battery Tray: Service and Repair Battery Tray Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in Restraint Systems. 2. Disconnect the negative battery cable. Important: This panel is replaced at factory seams. 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 6. Locate and drill out all the necessary factory welds. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Page 10217 7. On the sedan, structural adhesive is present at the joint between the battery tray and the rear floor pan. Heat the quarter panel at the locations shown with a small flame from an oxy-acetylene torch to release the bond to the quarter panel. 8. Remove the battery tray. Installation Procedure Important: The original battery tray has spot welds and bonding adhesive, but the service panel replacement will be MIG plug welded back together. Double the amount of factory welds in place of using the adhesive. 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 4. Position the battery tray to the vehicle. Clamp the battery tray in place. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Page 10218 Coatings. 9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings. 10. Connect the negative battery cable. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in Restraint Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10226 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10227 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10228 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10229 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10230 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10231 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10232 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10233 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10234 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10235 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10236 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10237 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10238 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10239 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10240 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10241 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10242 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10243 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10244 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10245 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10246 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10251 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10252 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10253 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10254 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10255 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10256 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10278 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10279 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10280 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10281 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10282 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10283 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10284 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10285 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10286 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10287 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10288 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10289 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 Alternator: Connector Views Generator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 Generator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 10301 Alternator: Service and Repair GENERATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect negative battery cable. 2. Remove the drive belt. 3. Remove the supercharger. 4. Remove the oil level indicator tube bolt and reposition the tube slightly for clearance. 5. Disconnect the generator connectors. 6. Remove the generator bolts. 7. Remove the generator from the vehicle. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 10302 1. Position the generator on the engine. 2. Install the generator bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the generator bolts to 25 N.m (18 lb ft). 3. Connect the positive battery harness to the generator battery terminal. Tighten the generator terminal nut to 20 N.m (15 lb ft). 4. Connect the generator harness connectors. 5. Position the oil level indicator tube into the correct installed position and install the retaining bolt. Tighten the bolt to 10 N.m (89 lb in). 6. Install the supercharger. 7. Install the drive belt. 8. Connect the battery negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 10312 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition > Page 10318 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Technical Service Bulletins > Page 10319 Clutch Switch: Locations Manual Transmission Component Views Pedal Components Pedal Components 1 - Clutch Pedal Position (CCP) Switch (M86) 2 - Clutch Start Switch (M86) 3 - Stop Lamp Switch 4 - Cruise Control Cancel Switch (M86) 5 - Accelerator Pedal Position (APP) Sensor 6 - Floor Pan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > M86 Clutch Switch: Diagrams M86 Clutch Pedal Position (CPP) Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > M86 > Page 10322 Clutch Start Switch (With RPO Code M86) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > M86 > Page 10323 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Adjustments > Old Pedal Clutch Switch: Adjustments Old Pedal Clutch Pedal Position Switch Adjustment (Old Pedal) Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Remove the CPP switch (1) from the clutch pedal by twisting the CPP switch (1) counterclockwise. Installation Procedure 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly and twist the CPP switch (1) clockwise to seat. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Remove the drill bit. 5. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Adjustments > Old Pedal > Page 10326 Clutch Switch: Adjustments New Pedal Clutch Pedal Position Switch Adjustment (New Pedal) Installation Procedure 1. While holding the pedal in the fully released position, press the switch (2) toward the pedal until the barrel of the switch (2) touches the shipping clip (1). 2. Remove the shipping clip (1). 3. Connect the electrical connector (3). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Adjustments > Page 10327 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position (CPP) switch (1). 2. Rotate the CPP switch (1) counterclockwise to release, and remove the switch from the clutch pedal assembly. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Adjustments > Page 10328 1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly. 2. Install the CPP switch (1) to the clutch pedal assembly. 3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly. 4. Rotate the switch (1) clockwise to secure. 5. Remove the drill bit. 6. Connect the electrical connector (2) to the CPP switch (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Locations Steering Wheel And Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Locations > Page 10333 Ignition Lock Solenoid: Service and Repair Ignition Lock Cylinder Solenoid Replacement Removal Procedure 1. Remove the steering column trim covers. 2. Disconnect the Ignition lock cylinder solenoid harness connector. 3. Remove the Ignition lock cylinder solenoid screws. 4. Important: Do not attempt to remove any roll pins retaining the plunger mechanism. The ignition lock cylinder solenoid replacement part consists of only the solenoid and spring. If the plunger mechanism exhibits any signs of damage or wear then replacement of the ignition lock cylinder case will be necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Locations > Page 10334 Remove the Ignition lock cylinder solenoid from the lock cylinder case housing. Installation Procedure 1. Important: Clean the solenoid and plunger with a lint free cloth prior to installation. Oil or debris may cause ignition lock cylinder solenoid malfunction. Install a new spring over the ignition lock cylinder solenoid plunger. 2. Carefully install the new ignition lock cylinder solenoid over the plunger. 3. Notice: Seat the ignition lock cylinder solenoid on the lock cylinder case housing and install the screws. ^ Tighten the screws to 2 Nm (17 inch lbs.). 4. Connect the lock cylinder solenoid harness connector. 5. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Locations > Page 10335 6. Check the operation of the ignition lock cylinder solenoid. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: Customer Interest A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10349 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10350 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10351 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-35-007A > Oct > 06 > Ignition Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 10360 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10370 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10371 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 10372 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 10381 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10395 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10396 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10397 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics Keyless Starting System: Technical Service Bulletins Remote Starting System - System Inoperative Diagnostics INFORMATION Bulletin No.: 08-08-52-002 Date: February 27, 2008 Subject: Diagnostic Information for Inoperative Remote Vehicle Start Models: 2005-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2008 HUMMER H2 with Remote Keyless Entry RPOs AP3 or AP8 Remote Vehicle Start (RVS) Inoperative Diagnostic Concerns Information on Hood Latch Switches One of the many components involved in the Remote Vehicle Starting System is the Hood Latch Switch. The state of this switch is checked by the BCM during a remote vehicle start request and the component must function properly in order for the vehicle to commence a remote start event. During the infancy of this option (RPO AP3/AP8) parts return analysis showed a significantly shorter than expected component life for the Hood Latch Switch shared across many different GM vehicles. The switches currently being factory installed, and sent as service replacement parts, are vastly improved in design and suitably robust. Most hood latch switches currently returned under warranty are analyzed and determined to have no trouble found (NTF). It is understandable and desirable that technicians gain familiarity with the vehicles they service on a daily basis, however it is required that technicians follow Strategy Based Diagnostics before replacing this switch. Important: The ONLY way to repair or replace a hood latch switch is to replace the LATCH ASSEMBLY. The switch CANNOT be serviced separately from the latch and is NOT AVAILABLE from GMSPO. Any effort to remove the switch from the latch will permanently damage the switch and void the warranty coverage of that part. Important: The hood switch provides status of the hood to the BCM for RVS purposes. The switch is integrated into the hood latch assembly. The hood ajar switch provides two separate inputs to the BCM. These separate inputs allow the BCM to actively monitor for a hood ajar switch fault. RVS System Operation The remote vehicle start (RVS) function allows engine starting while not in the vehicle. It also allows the vehicle HVAC system and other vehicle systems to enable providing a comfortable vehicle upon entry. RVS functions have an operating range of up to 59 m (195 ft) depending on conditions. The RVS sequence begins by pressing and releasing the lock button and then pressing and holding the RVS buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate the vehicle has received the remote start request. Each time an RVS is performed the vehicle doors are locked; however they may then be unlocked/locked with the transmitter or vehicle key at any time. Once activated the engine is allowed to run for 10 minutes. The RVS time may be extended by an additional 10 minutes by again pressing and releasing the lock button and then pressing and holding the RVS buttons on the transmitter. This feature is called an RVS continue and allows a maximum of 20 minutes of engine running. If the RVS continue is performed at 7 minutes into the initial 10 minute time-out a total of 17 minutes of engine running would occur. The RVS event may be suspended at any time by pressing only the RVS button on the transmitter or by entering the vehicle and turning ON the hazard lamps. RVS System Description Remote vehicle start (RVS) begins as a Radio Frequency (RF) message received by the remote control door lock receiver (RCDLR) from a keyless entry transmitter. The RVS request is sent by the RCDLR to the body control module (BCM) via serial data line. The BCM monitors system conditions such as content theft deterrent (CTD) closures ajar status and body DTCs to determine if an RVS event will occur. If conditions are determined to be acceptable the RVS message is sent to the engine control module (ECM). The ECM monitors system conditions such as engine control parameters and vehicle theft deterrent (VTD) to determine if engine starting will be allowed. If conditions are acceptable the ECM will initiate engine starting. During Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics > Page 10402 the engine run time in an RVS attempt before the operator enters the vehicle the ECM may discontinue engine operation if system conditions require it or a message is received from the BCM requesting the engine be turned OFF. Reasons an RVS event will NOT Happen The RVS System WILL NOT operate if any of the following conditions are present: ^ A current vehicle DTC that illuminates the malfunction indicator lamp (MIL) is set - obtain vehicle DTCs. ^ Keyless Entry Transmitter is not Operational. ^ The vehicle is in Valet Mode. ^ RVS is Disabled through Vehicle Personalization. ^ More than 2 Remote Starts have been attempted. ^ The HAZARD switch is in the ON position. ^ A current HAZARD switch DTC is set. ^ A current HOOD AJAR DTC is set. ^ Rear compartment lid is ajar. ^ Any Door is not locked. ^ The Content Theft Deterrent (CTD) system detects an alarm trigger. ^ Engine RPM greater than 0 Detected. ^ Excessive Coolant TEMP is registered. ^ Accelerator pedal position greater than 0 percent. ^ Vehicle is not in PARK. ^ A current Vehicle Theft Deterrent Malfunction DTC. ^ A current Automatic Transmission Shift Lock Control System DTC is set. ^ A vehicle speed sensor signal is detected by the ECM. ^ Vehicle power mode is incorrect. Diagnostic Information Starting Point For additional assistance refer to Remote Vehicle Start Inoperative in the Electronic Service Information. This section will guide you through the complete Strategy Based Diagnostics and provide Specific Diagnostic Procedure Instructions. Warranty Information Please refer to the published Labor Time Guides and claim the corresponding labor operation for the component(s) replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10407 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10408 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10409 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10410 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10411 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10412 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10413 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10414 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10415 Starter Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10416 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10417 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10418 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10419 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10420 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10421 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10422 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10423 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10424 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10425 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10426 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10427 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10428 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10429 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10430 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10431 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10432 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10433 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10434 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10435 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10436 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10437 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10438 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10439 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10440 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10441 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10442 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10443 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10444 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10445 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10446 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10447 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10448 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10449 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10450 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10451 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10452 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10453 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10454 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10455 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10456 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10457 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10458 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10459 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10460 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10461 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10462 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10463 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10464 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10465 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10466 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10467 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10468 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10469 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10470 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10471 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10472 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10473 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10474 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10475 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10478 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10479 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10480 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10481 Starter Motor: Service and Repair STARTER MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the intercooler pump outer bracket. 4. Disconnect the electrical connectors (3, 4, 5) from the starter. 5. Remove the starter bolts. 6. Remove the starter. INSTALLATION PROCEDURE 1. Install the starter. 2. Install the starter bolts. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10482 Tighten the starter bolts to 50 N.m (37 lb ft). 3. Connect the electrical connectors (4, 5) to the starter. Tighten the battery terminal nut to 11 N.m (97 lb in). 4. Connect the S-terminal connector (3) to the starter. Tighten the battery terminal nut to 3 N.m (27 lb in). 5. Install the intercooler pump outer bracket. Tighten the bolts to 20 N.m (15 lb ft). 6. Lower the vehicle. 7. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Front Lower Left Of The Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Console Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10506 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10508 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10509 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10510 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10511 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10512 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10513 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10514 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10515 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10516 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10517 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10518 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10519 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10520 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10521 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10522 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10523 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10524 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10525 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10526 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10527 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10528 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10529 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10530 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10531 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10532 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10533 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10534 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10535 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10536 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10537 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10538 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10539 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10540 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10541 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10542 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10543 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10544 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10545 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10546 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10547 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10548 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10549 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10550 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10551 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10552 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10553 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10554 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10555 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10556 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10557 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10558 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10559 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10560 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10561 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10562 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10563 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10564 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10565 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 Auxillary Power Outlet - Console Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover Fuse: Locations Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10573 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10574 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10575 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10576 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10577 Fuse: Locations Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10578 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10579 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10580 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10581 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10582 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10583 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse Holder - 50 AMP Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover Fuse: Application and ID Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10588 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10589 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10590 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10591 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10592 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10593 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10594 Fuse: Application and ID Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10595 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10596 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10597 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10598 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10599 Application Table Part 2 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10600 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - Underhood C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10605 Fuse Block - Underhood C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10606 Fuse Block - Underhood C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10607 Fuse Block - Underhood C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10608 Fuse Block - Underhood C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10609 Fuse Block - Underhood C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10610 Fuse Block - Underhood C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10611 Fuse Block - Underhood C4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10612 Fuse Block - Underhood C5 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10613 Fuse Block - Underhood C5 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10614 Fuse Block - Underhood C6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 10615 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 10616 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10621 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10622 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10623 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10624 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10625 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10626 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10635 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10641 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 Engine Harness to the Transmission Harness (With RPO Code MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10644 C102 Engine Harness to the Crankshaft Position Jumper C110 Forward Lamp Harness to the Headlamp Assembly - Right Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10645 C111 Forward Lamp Harness to the Headlamp Assembly - Left C121 Forward Lamp Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10646 C161 Engine Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10647 C162 Engine Harness to the Ignition Coil Harness C164 Engine Harness to the Fuel Injector Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10648 C170 Body Harness to the RF WSS Harness C171 Body Harness to the LF WSS Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10649 Multiple Junction Connector: Diagrams C200 - C299 C200 I/P Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10650 C201 I/P Harness to the Body Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10651 C201 I/P Harness to the Body Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10652 C201 I/P Harness to the Body Harness Part 3 C202 Body Harness to the Inflatable Restraint I/P Module - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10653 C204 Brake Jumper to the I/P Harness C210 I/P Harness to the HVAC Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10654 C275 I/P Harness to the SIR Coil Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10655 Multiple Junction Connector: Diagrams C300 - C399 C300 Body Harness to the Passenger Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10656 C300 Body Harness to the Passenger Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10657 C301 Body Harness to the Driver Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10658 C301 Body Harness to the Driver Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10659 C302 Headliner Harness to the Sun Roof Control Module (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10660 C305 EVAP Canister Purge Jumper Harness/Fuel Tank Harness/Wheel Speed Sensor Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10661 C314 Body Harness to the Passenger Seat Harness (With RPO Code KA1) C314 Body Harness to the Driver Seat Harness (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10662 C319 Body Harness to Left Roof Rail Module Harness (With RPO Code ASF) C320 Body Harness to Right Roof Rail Module Harness (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10663 C321 Body Harness to the Headliner Harness (With RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10664 C323 Body Harness to the Headliner Harness (Without RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10665 Multiple Junction Connector: Diagrams C400 - C499 C400 Battery Cable to the Body Harness C401 Body Harness to the Rear Compartment Lid Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10666 C492 Body Harness to the LR Tail Lamp Assembly Harness C493 Body Harness to the RR Tail Lamp Assembly Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10667 C494 Body Harness to the License Lamp Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10668 Multiple Junction Connector: Diagrams C100 Engine Harness to the Transmission Harness (With RPO Code MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10669 C102 Engine Harness to the Crankshaft Position Jumper C110 Forward Lamp Harness to the Headlamp Assembly - Right Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10670 C111 Forward Lamp Harness to the Headlamp Assembly - Left C121 Forward Lamp Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10671 C161 Engine Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10672 C162 Engine Harness to the Ignition Coil Harness C164 Engine Harness to the Fuel Injector Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10673 C170 Body Harness to the RF WSS Harness C171 Body Harness to the LF WSS Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10674 C200 I/P Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10675 C201 I/P Harness to the Body Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10676 C201 I/P Harness to the Body Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10677 C201 I/P Harness to the Body Harness Part 3 C202 Body Harness to the Inflatable Restraint I/P Module - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10678 C204 Brake Jumper to the I/P Harness C210 I/P Harness to the HVAC Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10679 C275 I/P Harness to the SIR Coil Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10680 C300 Body Harness to the Passenger Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10681 C300 Body Harness to the Passenger Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10682 C301 Body Harness to the Driver Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10683 C301 Body Harness to the Driver Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10684 C302 Headliner Harness to the Sun Roof Control Module (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10685 C305 EVAP Canister Purge Jumper Harness/Fuel Tank Harness/Wheel Speed Sensor Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10686 C314 Body Harness to the Passenger Seat Harness (With RPO Code KA1) C314 Body Harness to the Driver Seat Harness (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10687 C319 Body Harness to Left Roof Rail Module Harness (With RPO Code ASF) C320 Body Harness to Right Roof Rail Module Harness (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10688 C321 Body Harness to the Headliner Harness (With RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10689 C323 Body Harness to the Headliner Harness (Without RPO Code UE1) C400 Battery Cable to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10690 C401 Body Harness to the Rear Compartment Lid Harness C492 Body Harness to the LR Tail Lamp Assembly Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10691 C493 Body Harness to the RR Tail Lamp Assembly Harness C494 Body Harness to the License Lamp Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10692 C700 Body Harness to the LR Door Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10693 C800 Body Harness to the RR Door Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10694 SP200 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Page 10699 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Page 10703 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10712 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10713 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10714 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10719 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10725 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10726 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10727 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10732 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10733 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10734 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10735 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10736 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10737 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10742 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10747 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10753 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10754 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10755 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10756 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10757 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10758 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10763 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Console Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10770 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10771 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10772 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10773 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10774 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10775 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10776 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10777 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10778 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10779 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10780 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10781 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10782 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10783 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10784 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10785 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10786 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10787 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10788 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10789 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10790 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10791 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10792 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10793 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10794 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10795 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10796 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10797 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10798 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10799 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10800 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10801 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10802 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10803 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10804 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10805 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10806 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10807 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10808 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10809 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10810 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10811 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10812 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10813 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10814 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10815 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10816 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10817 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10818 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10819 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10820 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10821 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10822 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10823 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10824 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10825 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10826 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10827 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10828 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10829 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10830 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10831 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10832 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10833 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10834 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10835 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10836 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10837 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10838 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10839 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10840 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10841 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10842 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10843 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10844 Auxillary Power Outlet - Console Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover Fuse: Locations Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10851 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10852 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10853 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10854 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10855 Fuse: Locations Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10856 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10857 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10858 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10859 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10860 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Body Control Module (BCM) - Cover > Page 10861 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse Holder - 50 AMP Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover Fuse: Application and ID Body Control Module (BCM) - Cover Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10866 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10867 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10868 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10869 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10870 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10871 Application Table Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10872 Fuse: Application and ID Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10873 Application Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10874 Location View Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10875 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10876 Application Table Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10877 Application Table Part 2 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Body Control Module (BCM) - Cover > Page 10878 Location View Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - Underhood C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10883 Fuse Block - Underhood C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10884 Fuse Block - Underhood C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10885 Fuse Block - Underhood C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10886 Fuse Block - Underhood C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10887 Fuse Block - Underhood C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10888 Fuse Block - Underhood C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10889 Fuse Block - Underhood C4 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10890 Fuse Block - Underhood C5 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10891 Fuse Block - Underhood C5 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10892 Fuse Block - Underhood C6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 10893 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 10894 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10899 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10900 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10901 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10902 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10903 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10904 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 10913 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10919 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 Multiple Junction Connector: Diagrams C100 - C199 C100 Engine Harness to the Transmission Harness (With RPO Code MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10922 C102 Engine Harness to the Crankshaft Position Jumper C110 Forward Lamp Harness to the Headlamp Assembly - Right Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10923 C111 Forward Lamp Harness to the Headlamp Assembly - Left C121 Forward Lamp Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10924 C161 Engine Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10925 C162 Engine Harness to the Ignition Coil Harness C164 Engine Harness to the Fuel Injector Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10926 C170 Body Harness to the RF WSS Harness C171 Body Harness to the LF WSS Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10927 Multiple Junction Connector: Diagrams C200 - C299 C200 I/P Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10928 C201 I/P Harness to the Body Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10929 C201 I/P Harness to the Body Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10930 C201 I/P Harness to the Body Harness Part 3 C202 Body Harness to the Inflatable Restraint I/P Module - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10931 C204 Brake Jumper to the I/P Harness C210 I/P Harness to the HVAC Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10932 C275 I/P Harness to the SIR Coil Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10933 Multiple Junction Connector: Diagrams C300 - C399 C300 Body Harness to the Passenger Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10934 C300 Body Harness to the Passenger Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10935 C301 Body Harness to the Driver Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10936 C301 Body Harness to the Driver Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10937 C302 Headliner Harness to the Sun Roof Control Module (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10938 C305 EVAP Canister Purge Jumper Harness/Fuel Tank Harness/Wheel Speed Sensor Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10939 C314 Body Harness to the Passenger Seat Harness (With RPO Code KA1) C314 Body Harness to the Driver Seat Harness (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10940 C319 Body Harness to Left Roof Rail Module Harness (With RPO Code ASF) C320 Body Harness to Right Roof Rail Module Harness (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10941 C321 Body Harness to the Headliner Harness (With RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10942 C323 Body Harness to the Headliner Harness (Without RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10943 Multiple Junction Connector: Diagrams C400 - C499 C400 Battery Cable to the Body Harness C401 Body Harness to the Rear Compartment Lid Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10944 C492 Body Harness to the LR Tail Lamp Assembly Harness C493 Body Harness to the RR Tail Lamp Assembly Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10945 C494 Body Harness to the License Lamp Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10946 Multiple Junction Connector: Diagrams C100 Engine Harness to the Transmission Harness (With RPO Code MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10947 C102 Engine Harness to the Crankshaft Position Jumper C110 Forward Lamp Harness to the Headlamp Assembly - Right Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10948 C111 Forward Lamp Harness to the Headlamp Assembly - Left C121 Forward Lamp Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10949 C161 Engine Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10950 C162 Engine Harness to the Ignition Coil Harness C164 Engine Harness to the Fuel Injector Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10951 C170 Body Harness to the RF WSS Harness C171 Body Harness to the LF WSS Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10952 C200 I/P Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10953 C201 I/P Harness to the Body Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10954 C201 I/P Harness to the Body Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10955 C201 I/P Harness to the Body Harness Part 3 C202 Body Harness to the Inflatable Restraint I/P Module - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10956 C204 Brake Jumper to the I/P Harness C210 I/P Harness to the HVAC Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10957 C275 I/P Harness to the SIR Coil Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10958 C300 Body Harness to the Passenger Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10959 C300 Body Harness to the Passenger Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10960 C301 Body Harness to the Driver Door Harness Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10961 C301 Body Harness to the Driver Door Harness Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10962 C302 Headliner Harness to the Sun Roof Control Module (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10963 C305 EVAP Canister Purge Jumper Harness/Fuel Tank Harness/Wheel Speed Sensor Harness to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10964 C314 Body Harness to the Passenger Seat Harness (With RPO Code KA1) C314 Body Harness to the Driver Seat Harness (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10965 C319 Body Harness to Left Roof Rail Module Harness (With RPO Code ASF) C320 Body Harness to Right Roof Rail Module Harness (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10966 C321 Body Harness to the Headliner Harness (With RPO Code UE1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10967 C323 Body Harness to the Headliner Harness (Without RPO Code UE1) C400 Battery Cable to the Body Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10968 C401 Body Harness to the Rear Compartment Lid Harness C492 Body Harness to the LR Tail Lamp Assembly Harness Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10969 C493 Body Harness to the RR Tail Lamp Assembly Harness C494 Body Harness to the License Lamp Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10970 C700 Body Harness to the LR Door Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10971 C800 Body Harness to the RR Door Harness (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C199 > Page 10972 SP200 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Page 10977 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the cover (2) from the underhood electrical center. 3. Remove the underhood positive battery terminal lug (4). 4. Disconnect the positive battery cables (5) from the underhood electrical center. IMPORTANT: Take note of the positioning of the positive battery cables before disconnecting the cables. 5. Loosen all of the underhood electrical bolts (3). IMPORTANT: The underhood electrical center bolts (3) are retained in the electrical center. 6. Remove the underhood electrical center (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the underhood electrical center (1) to the vehicle. 2. Tighten the underhood electrical bolts to 10 N.m (89 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the positive battery cables (5) to the underhood electrical center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Page 10981 4. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 15 N.m (133 lb in). 5. Install the cover (2) to the underhood electrical center. 6. Connect the negative battery cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10990 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10991 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10992 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10997 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11003 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11004 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11005 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11010 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11011 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11012 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11013 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11014 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11015 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11020 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 11025 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11031 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11032 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11033 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11034 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11035 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11036 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 11041 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11047 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11048 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11049 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11050 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11051 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11052 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 11053 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications The content of this article reflects the changes identified in TSB 05-03-06-003. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 11056 Alignment: Specifications Wheel Alignment Specifications Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 11057 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11058 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11059 Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11060 If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ A large difference in the right and left front tire pressure ^ Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11061 Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11062 Alignment: Service and Repair Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Front Camber Adjustment 1. Loosen both strut to knuckle nuts just enough to allow for movement. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 11063 2. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. 2. File the lower hole until the groove of the stamped ring around the hole. 3. Connect the strut to the knuckle. 3. Adjust the camber to specification by moving the top of the wheel in or out. Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (5). 3. Adjust the toe to specification by turning the adjuster (6). Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the tie rod jam nut (5). ^ Tighten the tie rod jam nut (5) to 68 Nm (50 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Steering Wheel and Column Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11069 Steering Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11070 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11071 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11087 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available Front Steering Knuckle: Technical Service Bulletins Steering - Competition Steering Knuckles Available Bulletin No.: 06-03-08-001D Date: September 27, 2006 INFORMATION Subject: Availability of Steering Knuckles for Competitive Driving Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2004-2007 Saturn ION, ION Redline Supercede: This bulletin is being revised to add a statement in the Alternate Steering Knuckles section. Please discard Corporate Bulletin Number 06-03-08-001C (Section 03 - Suspension). Alternate Steering Knuckles This is to advise owners who intend to use their vehicles for competitive driving, of the availability of alternate steering knuckles, and to provide recommended alignment specifications for those owners who use their vehicles for competitive driving. These steering knuckles are available through GM service parts and are suggested for use on the Cobalt (Pursuit)/ION Redline. Refer to the Parts Information below for ordering instructions. (This steering knuckle may also be installed and the alignment specifications used, at the customer's discretion, for non-competition purposes.) Replacement Procedure Service replacement instructions can be found in SI (Steering Knuckle Replacement). Alignment Settings The alignment following settings provide for even tire wear in competitive driving. Please use the alignment specifications shown for competitive driving only. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available > Page 11093 Parts Information Warranty Information The above modifications are considered to be a customer option and should be performed at the customer's expense. Prior to using your vehicle for competitive driving, refer to your vehicle warranty book or General Motors dealership for information on the General Motors new vehicle factory warranty, and how competitive driving may effect your warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available > Page 11094 Front Steering Knuckle: Technical Service Bulletins Steering - Revised Tie Rod to Steering Knuckle Torque Bulletin No.: 05-03-08-017 Date: December 06, 2005 SERVICE MANUAL UPDATE Subject: Revised Steering Linkage Outer Tie Rod-to-Steering Knuckle Nut Tightening Specification Models: 2005 Chevrolet Cobalt, Equinox 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION, VUE This bulletin is being issued to revise the steering linkage outer tie rod-to-steering knuckle nut tightening specification in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Revised Torque TSB # 05-03-08-017 Dated 12/06/2005 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11095 Front Steering Knuckle: Service and Repair The content of this article reflects the changes identified in TSB Bulletin No. #05-03-08-017 dated December 06, 2005. SUBJECT: Steering Linkage Outer Tie Rod-to-Steering Knuckle Nut Torque Revised Torque TSB # 05-03-08-017 Dated 12/06/2005 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11096 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11097 Steering Knuckle Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Information not provided by the manufacturer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 11103 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist Technical Service Bulletin # 10023D Date: 100916 Recall - Loss Of Power Steering Assist SAFETY Bulletin No.: 10023D Date: September 16, 2010 Subject: 10023D - Loss of Power Steering Assist - Replace Electric Power Steering Motor Models: 2005-2010 Chevrolet Cobalt 2005 Pontiac Pursuit 2005-2006 Pontiac G4 2006 Pontiac G5 Pursuit 2007-2010 Pontiac G5 Equipped with Electric Power Steering Supercede: The Parts Information, Service Procedure, and Claim Information sections in this bulletin have been revised. Dealers are to no longer use Loctite. All reference to the use of Loctite has been removed. Additional motor kit part numbers have also been added to the Parts Information table. Please discard all copies of bulletin 10023C, issued June 2010. The vehicles involved in this safety recall were placed on Stop Delivery on March 2, 2010. Performing the service procedure contained in this bulletin will release the vehicle from Stop Delivery and allow you to sell and delivery the vehicle to a customer. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering. Some of these vehicles have a condition in which a sudden loss of power steering assist could occur at any time while driving the vehicle. If the power steering assist is lost, a chime will sound and a "Power Steering" message will be displayed in the Driver Information Center to inform the driver of the condition. Steering control will be maintained, as the vehicle defaults to a manual steering mode. If power steering assist is lost, it may require greater driver effort at low vehicle speeds, for example, below 15 mph (25 km/h). Unless a driver compensates for this additional effort, it may increase the risk of a crash. Typically, the next time the vehicle is started, the power steering assist will return and the "Power Steering" message will no longer be displayed. Correction Dealers are to replace the electric power steering motor. Vehicles Involved Involved are certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering, and built within these VIN breakpoints: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11112 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Important An initial supply of motor kits required to complete this recall were pre-shipped to involved dealers of record. This pre-shipment took place the week of March 15, 2010. Parts required for this recall have been excluded from RIM. Additional dealer inventory should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. * A $40 core charge has been added to this part. Service Procedure Note For customers applying for reimbursement, check GWM to determine if the new power steering motor was installed. - If the new motor was installed, no further action is required. Proceed to the Claim Information section. - If the new motor was NOT installed, the vehicle requires motor replacement. Proceed to the repair instructions below. EPS Motor Replacement Procedure Note The use of Loctite is no longer required. Loctite should not be used for any further applications. 1. Connect the Tech 2(R) to the vehicle and check for diagnostic trouble codes (DTCs). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11113 2. Record any present DTCs on the repair order and during claim submission. 3. Clear any DTCs that are present. 4. Remove the power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI. Caution Use caution when installing the new motor assembly to prevent damage to the components on the front of the motor assembly. When installing the new motor assembly, hold the motor assembly in vehicle position and finger start and tighten the two bolts. Technicians must tighten the two power steering motor bolts evenly, alternating between the two bolts until proper torque is obtained. If the motor is not held in vehicle position and bolts are not finger started and tightened properly, a noise or vibration may be induced into the steering column. Note For 2005 model year vehicles only: Do NOT install the o-ring between the motor assembly and the steering column assembly. The new service motor kit will include an o-ring but DO NOT use the o-ring for 2005 model year vehicles only. 5. Install the new power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI. 6. Perform Test Drive. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by October 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Floor Plan Reimbursement Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this recall. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the recall parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a net amount expense using the recall labor operation provided. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11114 2. Courtesy Transportation (not for Export use) - Submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. ** The amount identified in "Net Item" should represent the product of the vehicle's average daily interest rate (see table below) multiplied by the actual number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop delivery message (March 2, 2010) to the date the repair is completed and the vehicle is ready for sale (not to exceed 35 days): Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11115 Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10023. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a condition in which a sudden loss of power steering assist could occur at any time while driving the vehicle. If the power steering assist is lost, a chime will sound and a "Power Steering" message will be displayed in the Driver Information Center to inform you of the condition. Steering control will be maintained, as the vehicle defaults to a manual steering mode. If power steering assist is lost, it may require greater driver effort at low vehicle speeds, for example, below 15 mph (25 km/h). Unless the driver compensates for this additional effort, it may increase the risk of a crash. Typically, the next time the vehicle is started, the power steering assist will return and the "Power Steering" message will no longer be displayed. What will we do? Your GM dealer will replace the electric power steering motor. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 40 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. If you had this condition corrected, you may have received the new motor. Please contact your dealer to determine if the motor in your vehicle requires replacement. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11116 If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10023 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Recalls: > NHTSA10V073000 > Mar > 10 > Recall 10V073000: Power Steering Motor Replacement Power Steering Motor: Recalls Recall 10V073000: Power Steering Motor Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Cobalt 2005-2010 Pontiac/G5 2007-2010 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: March 01, 2010 NHTSA CAMPAIGN ID NUMBER: 10V073000 NHTSA ACTION NUMBER: N/A COMPONENT: Steering: Electric Power Assist System POTENTIAL NUMBER OF UNITS AFFECTED: 1050889 SUMMARY: General Motors is recalling certain model year 2005-2010 Chevrolet Cobalt and model year 2007-2010 Pontiac G5 vehicles equipped with electric power steering. The driver may experience a sudden loss of power steering assist that could occur at any time while driving. CONSEQUENCE: If power steering assist is lost, it would require greater driver effort at low vehicle speeds, increasing the risk of a crash. REMEDY: Dealers will replace the electric power steering motor free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact Chevrolet at 1-800-630-2438 and Pontiac at 1-800-620-7668 or at the owner center at www.gmownercenter.com. NOTES: GM's recall No. 10023. Owners may also contact the National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist Technical Service Bulletin # 10023D Date: 100916 Recall - Loss Of Power Steering Assist SAFETY Bulletin No.: 10023D Date: September 16, 2010 Subject: 10023D - Loss of Power Steering Assist - Replace Electric Power Steering Motor Models: 2005-2010 Chevrolet Cobalt 2005 Pontiac Pursuit 2005-2006 Pontiac G4 2006 Pontiac G5 Pursuit 2007-2010 Pontiac G5 Equipped with Electric Power Steering Supercede: The Parts Information, Service Procedure, and Claim Information sections in this bulletin have been revised. Dealers are to no longer use Loctite. All reference to the use of Loctite has been removed. Additional motor kit part numbers have also been added to the Parts Information table. Please discard all copies of bulletin 10023C, issued June 2010. The vehicles involved in this safety recall were placed on Stop Delivery on March 2, 2010. Performing the service procedure contained in this bulletin will release the vehicle from Stop Delivery and allow you to sell and delivery the vehicle to a customer. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering. Some of these vehicles have a condition in which a sudden loss of power steering assist could occur at any time while driving the vehicle. If the power steering assist is lost, a chime will sound and a "Power Steering" message will be displayed in the Driver Information Center to inform the driver of the condition. Steering control will be maintained, as the vehicle defaults to a manual steering mode. If power steering assist is lost, it may require greater driver effort at low vehicle speeds, for example, below 15 mph (25 km/h). Unless a driver compensates for this additional effort, it may increase the risk of a crash. Typically, the next time the vehicle is started, the power steering assist will return and the "Power Steering" message will no longer be displayed. Correction Dealers are to replace the electric power steering motor. Vehicles Involved Involved are certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering, and built within these VIN breakpoints: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11126 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Important An initial supply of motor kits required to complete this recall were pre-shipped to involved dealers of record. This pre-shipment took place the week of March 15, 2010. Parts required for this recall have been excluded from RIM. Additional dealer inventory should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. * A $40 core charge has been added to this part. Service Procedure Note For customers applying for reimbursement, check GWM to determine if the new power steering motor was installed. - If the new motor was installed, no further action is required. Proceed to the Claim Information section. - If the new motor was NOT installed, the vehicle requires motor replacement. Proceed to the repair instructions below. EPS Motor Replacement Procedure Note The use of Loctite is no longer required. Loctite should not be used for any further applications. 1. Connect the Tech 2(R) to the vehicle and check for diagnostic trouble codes (DTCs). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11127 2. Record any present DTCs on the repair order and during claim submission. 3. Clear any DTCs that are present. 4. Remove the power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI. Caution Use caution when installing the new motor assembly to prevent damage to the components on the front of the motor assembly. When installing the new motor assembly, hold the motor assembly in vehicle position and finger start and tighten the two bolts. Technicians must tighten the two power steering motor bolts evenly, alternating between the two bolts until proper torque is obtained. If the motor is not held in vehicle position and bolts are not finger started and tightened properly, a noise or vibration may be induced into the steering column. Note For 2005 model year vehicles only: Do NOT install the o-ring between the motor assembly and the steering column assembly. The new service motor kit will include an o-ring but DO NOT use the o-ring for 2005 model year vehicles only. 5. Install the new power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI. 6. Perform Test Drive. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by October 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Floor Plan Reimbursement Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this recall. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the recall parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a net amount expense using the recall labor operation provided. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11128 2. Courtesy Transportation (not for Export use) - Submit as Net Item under the repair labor code. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. ** The amount identified in "Net Item" should represent the product of the vehicle's average daily interest rate (see table below) multiplied by the actual number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop delivery message (March 2, 2010) to the date the repair is completed and the vehicle is ready for sale (not to exceed 35 days): Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11129 Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2005-2010 model year Chevrolet Cobalt vehicles; 2005 model year Pontiac Pursuit; 2005-2006 model year Pontiac G4; 2006 model year Pontiac G5 Pursuit; and 2007-2010 model year Pontiac G5 vehicles equipped with electric power steering. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10023. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a condition in which a sudden loss of power steering assist could occur at any time while driving the vehicle. If the power steering assist is lost, a chime will sound and a "Power Steering" message will be displayed in the Driver Information Center to inform you of the condition. Steering control will be maintained, as the vehicle defaults to a manual steering mode. If power steering assist is lost, it may require greater driver effort at low vehicle speeds, for example, below 15 mph (25 km/h). Unless the driver compensates for this additional effort, it may increase the risk of a crash. Typically, the next time the vehicle is started, the power steering assist will return and the "Power Steering" message will no longer be displayed. What will we do? Your GM dealer will replace the electric power steering motor. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 40 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. If you had this condition corrected, you may have received the new motor. Please contact your dealer to determine if the motor in your vehicle requires replacement. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 10023D > Sep > 10 > Recall - Loss Of Power Steering Assist > Page 11130 If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10023 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > NHTSA10V073000 > Mar > 10 > Recall 10V073000: Power Steering Motor Replacement Power Steering Motor: All Technical Service Bulletins Recall 10V073000: Power Steering Motor Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Cobalt 2005-2010 Pontiac/G5 2007-2010 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: March 01, 2010 NHTSA CAMPAIGN ID NUMBER: 10V073000 NHTSA ACTION NUMBER: N/A COMPONENT: Steering: Electric Power Assist System POTENTIAL NUMBER OF UNITS AFFECTED: 1050889 SUMMARY: General Motors is recalling certain model year 2005-2010 Chevrolet Cobalt and model year 2007-2010 Pontiac G5 vehicles equipped with electric power steering. The driver may experience a sudden loss of power steering assist that could occur at any time while driving. CONSEQUENCE: If power steering assist is lost, it would require greater driver effort at low vehicle speeds, increasing the risk of a crash. REMEDY: Dealers will replace the electric power steering motor free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact Chevrolet at 1-800-630-2438 and Pontiac at 1-800-620-7668 or at the owner center at www.gmownercenter.com. NOTES: GM's recall No. 10023. Owners may also contact the National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Motor: > 06-02-32-013B > Aug > 09 > Steering - Power Steering Pump Replacement Tips Power Steering Motor: All Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Motor: > 06-02-32-013B > Aug > 09 > Steering - Power Steering Pump Replacement Tips Power Steering Motor: All Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Steering Wheel and Column Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 11147 Steering Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 11148 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 11149 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Steering Wheel and Column Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11154 Steering Control Module: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11155 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 11156 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11162 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11163 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11164 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11165 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11166 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11167 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11168 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11169 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11170 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11171 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11172 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11173 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11174 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11175 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11176 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11177 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11178 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11179 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11180 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11181 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11182 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11183 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11184 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11185 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11186 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11187 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 11188 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair Steering Gear: Service and Repair The content of this article reflects the changes identified in TSB Bulletin No. #05-03-08-017 dated December 06, 2005. SUBJECT: Steering Linkage Outer Tie Rod-to-Steering Knuckle Nut Torque Power Steering Gear Replacement ^ Tools Required J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Turn the steering wheel to the straight ahead position and remove the key from the ignition. 2. Turn the wheel counter clockwise in order to lock the steering column in place. 3. Raise and support the vehicle. 4. Remove the front wheels. 5. Important: Do not rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur. Remove the steering gear to intermediate shaft pinch bolt and discard. 6. Disconnect the intermediate shaft from the steering gear. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 11192 7. Remove both steering gear outer tie rod to knuckle nuts and discard the nuts. 8. Important: Do not attempt to separate the joint using a wedge type tool. Use the J 24319-B to separate the outer tie rods from the steering knuckles. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 11193 9. Remove the steering gear bolts. 10. Carefully remove the steering gear from the frame and the vehicle through the LH wheel opening. Installation Procedure 1. Install the steering gear to the frame through the LH wheel opening. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the steering gear bolts. ^ Tighten the bolts to 110 Nm (81 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 11194 3. Connect the intermediate shaft to the steering gear. 4. Install a new intermediate shaft pinch bolt. ^ Tighten the bolts to 34 Nm (25 ft. lbs.). 5. Install the outer tie rods to the steering knuckles. 6. Install new outer tie rod nuts. - Tighten the steering linkage outer tie rod-to-steering knuckle nut to 25 Nm (18 lb ft) Plus 90 degrees 7. Install the front wheels. 8. Lower the vehicle. 9. Adjust the toe if necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11199 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11200 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11201 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11202 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11203 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11204 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11205 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11206 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11207 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11208 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11209 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11210 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11211 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11212 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11213 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11214 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11215 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11216 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11217 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11218 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11219 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11220 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11221 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11222 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11223 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11224 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11225 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11226 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11227 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11228 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11229 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11230 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11231 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11233 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11234 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11235 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11236 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11237 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11238 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11239 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11240 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11241 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11242 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11243 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11244 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11245 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11246 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11247 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11248 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11249 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11250 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11251 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11252 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11253 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11254 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11255 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11256 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11257 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11258 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11259 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11260 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11261 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11262 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11263 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11264 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11265 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11266 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11267 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11268 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11269 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11270 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11271 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11272 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 11273 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Steering Shaft: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11282 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11283 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11284 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11285 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11286 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11287 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11288 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Steering Shaft: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11294 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11295 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11296 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11297 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11298 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11299 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11300 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Thermostat: All Technical Service Bulletins Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored Bulletin No.: 05-06-04-038D Date: April 13, 2006 TECHNICAL Subject: 2.0L LSJ Engine SES Lamp Illuminated with DTC P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" Set (Reprogram PCM) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with Supercharged 2.0L Four-Cylinder Engine (VIN P - RPO LSJ) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 05-06-04-038C (Section 06 - Engine). Condition Some customers may comment that the Service Engine Soon (SES) lamp is illuminated. Diagnostic Trouble Code (DTC) P0128 "Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature" may be set. Cause Under certain ambient engine temperature conditions, the thermostatically controlled engine coolant temperature may not reach the calibrated threshold in the allotted time frame that is programmed in the PCM. Correction Follow the steps outlined in the "Service Procedure" section of this bulletin to repair a false DTC P0128. Service Procedure Verify operation of the thermostat and cooling system. Refer to "DTC P0128" diagnostic in published Service Information. Before replacing the engine coolant thermostat and/or updating PCM calibration for repairing a false DTC P0128. Perform the following service procedures: 1. Observe the coolant temperature within the P0128 Freeze Frame. ^ If the engine coolant temperature is greater than 70.25°C (158.25°F) with DTC P0128, the PCM needs the updated calibration. Do not replace the engine coolant thermostat. ^ If the engine coolant temperature is less than 70.25°C (158.25°F) with DTC P0128, replace only the engine coolant thermostat. Important: Chevrolet Dealers: The PCM calibration is available to dealerships as part of TIS2000 incremental satellite update version 4.0, which was broadcast to dealers in April, 2006 or later. For the dealerships that use CDs, they were mailed out April, 2006 or later. Important: Saturn Retailers: Before installing the new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 4.0 2006 or later. Important: While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures. Important: Technician must select the "Reprogram" option in order to reprogram the PCM. 2. Reprogram the PCM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0128 concern. Refer to "Service Programming System (SPS)" in SI for reprogramming procedures. As always, make sure your Tech 2(R) is updated with the latest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 11306 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 05-06-04-038D > Apr > 06 > Engine Controls - SES/MIL Lamp ON/DTC P0128 Stored > Page 11312 software version. Warranty Information If PCM Programming Was Performed: For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use the table. If Thermostat Was Replaced: For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 11313 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the left front tire. 3. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt. 4. Disconnect the intermediate shaft from the steering gear. 5. Lower the vehicle. 6. Align the steering wheel into the straight forward position. 7. Important: Locking of the steering column will prevent damage and a possible malfunction of the SIR system. Remove the ignition key and turn the steering wheel clockwise until it locks. 8. Place scribe marks on the intermediate shaft to the steering column connection prior to removal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 11314 9. Remove the intermediate shaft pinch bolt at the steering column. Discard the pinch bolt. 10. Slide the intermediate shaft off the steering column shaft. 11. Use a pulling, squeezing and twisting motion to unseat the intermediate shaft seal from the dash. 12. Remove the intermediate shaft/seal from the vehicle. Installation Procedure 1. Important: Failure to transfer the pre-scribed marks may result in an off-center steering wheel. If installing a new intermediate shaft, transfer the pre-scribed alignment marks onto the new part. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 11315 2. Install the intermediate shaft/seal through the front of dash. 3. Important: To ensure seal is properly seated, inspect the seal from the engine side of the seal. Seat the intermediate shaft seal using a pushing, squeezing and twisting motion until seal is fully seated. 4. Align the pre-scribed mark on the intermediate shaft to the pre-scribed mark on the steering column shaft. 5. Connect the intermediate shaft to the steering column shaft. 6. If the intermediate shaft was removed without the use of a scribed mark, perform the following: 1. Place the road wheels in the straight ahead position. 2. Install the intermediate shaft to the steering gear so the intermediate shaft bolt head faces the LH wheel well opening. 3. Place the steering wheel in the straight ahead position. 4. Connect the intermediate shaft to the steering column shaft. 7. Notice: Install a new intermediate shaft to steering column pinch bolt. ^ Tighten the bolt to 34 Nm (25 ft. lbs.). 8. Connect the intermediate shaft to the steering gear. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 11316 9. Install a new intermediate shaft to steering gear pinch bolt. ^ Tighten the bolt to 34 Nm (25 ft. lbs.). 10. Install the left front wheel. 11. Check for proper steering wheel alignment. If steering wheel is out of alignment perform the following: 1. Remove the intermediate shaft pinch bolt at the steering column. 2. Disconnect the intermediate shaft in order to rotate and reconnect as needed to straighten the steering alignment. 3. Install a new intermediate shaft pinch bolt. ^ Tighten the bolt to 34 Nm (25 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering - Revised Steering Wheel Replacement Procedure Steering Wheel: Technical Service Bulletins Steering - Revised Steering Wheel Replacement Procedure Bulletin No.: 05-02-35-008A Date: February 13, 2006 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to update the steering wheel puller legs special tool. Please discard Corporate Bulletin Number 05-02-35-008 (Section 02 - Steering). This bulletin is being issued to revise the Steering Wheel Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering - Revised Steering Wheel Replacement Procedure > Page 11321 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering - Revised Steering Wheel Replacement Procedure > Page 11322 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 11323 Steering Wheel: Diagrams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 11324 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 11325 Steering Wheel: Description and Operation Steering Wheel and Column Description and Operation The steering wheel and column has 4 primary functions: ^ Vehicle steering ^ Vehicle security ^ Driver convenience ^ Driver safety Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security-Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: ^ The ignition switch ^ The steering column lock ^ The ignition cylinder Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. ^ The turn signal switch ^ The hazard switch ^ The headlamp dimmer switch ^ The wiper/washer switch ^ The horn pad/cruise control switch ^ The tilt or tilt/telescoping functions Driver Safety The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The mounting capsules break away from the mounting bracket in the event of an accident. Ignition Lock Cylinder Control Actuator If the vehicle is equipped with a floor mounted console gear shifter, it has a ignition lock cylinder control actuator system in the steering column. The ignition lock cylinder control actuator's purpose is to prevent the ignition key from being turned to the OFF position when the transmission is in gear and the vehicle may still be moving. The column ignition lock system consists of a ignition lock cylinder control actuator, and a park position switch that is located in the A/T shift lock control switch. The ignition lock cylinder control actuator contains a pin that is spring loaded out to mechanically prevent the ignition key cylinder from being turned to the lock position when vehicle transmission is not in the Park position. If vehicle power is lost, and/or the transmission is not in the Park position the operator will not be able to turn the ignition key to the lock position and will not be able to remove the ignition key from the column. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement Steering Wheel: Service and Repair Steering Wheel Replacement The content of this article reflects the changes identified in TSB- 05-02-35-008 Dated: December 09, 2005 Steering Wheel Components Steering Wheel Components Steering Wheel Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 11328 Steering Wheel Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 11329 Steering Wheel: Service and Repair Steering Wheel Shroud Replacement Steering Wheel Shroud Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Page 11330 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair Rack and Pinion Boot Replacement - On Vehicle ^ Tools Required J 22610 Keystone Clamp Pliers Removal Procedure 1. Raise and support the vehicle. 2. Remove the front wheel. 3. Remove the outer tie rod end. 4. Remove the outer to inner tie rod jam nut and discard. 5. Remove the outer steering gear boot spring clamp. 6. Using cutters, cut the inner steering gear boot clamp, remove and discard. 7. Disengage the steering gear boot from the steering gear and remove over the inner tie rod. 8. Inspect the sealing surfaces and threaded shaft portion of the steering gear and inner tie rod. The surfaces must be clean and free of debris. Installation Procedure 1. Install a new clamp on the inner portion of the steering gear boot. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 11335 2. Apply grease from the service kit to the indicated locations. 3. Important: The boot must seat in the groove in the steering gear. Install the boot over the inner tie rod onto the steering gear. 4. Using the J 22610, crimp the inner boot clamp on the steering gear housing. 5. Install the small spring clamp on the outer portion of the inner tie rod end. 6. Install a new outer to inner tie rod jam nut. 7. Install the outer tie rod end. 8. Install the wheel. 9. Set the toe. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball joint wear limit ............................................................................................................................... .................................................. 3.18 mm (0.128 in) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 11340 Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 11341 Ball Joint: Service and Repair Lower Ball Joint Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the lower control arm. 3. Place the lower control arm in a vise. 4. Remove the ball joint to control arm rivets using the following procedure: A.Use a 3 mm (1/8 inch) drill bit in order to make a pilot hole through the rivets. B.Use a 13 mm (31/64 inch) drill bit to complete drilling the rivets. 5. Remove the ball joint from the lower control arm. Installation Procedure 1. Install the ball joint to the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the ball joint bolts and the nuts. Follow the instructions in the ball joint kit. ^ Tighten the ball joint bolts to 68 Nm (50 ft. lbs.). 3. Install the lower control arm. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Control Arm Bushing: Customer Interest Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Control Arm Bushing: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11355 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11356 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11357 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11358 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11359 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11360 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11361 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > j06-03-09-005 > Jun > 06 > Suspension - Rear Suspension Squeaks on Bumps Control Arm Bushing: Customer Interest Suspension - Rear Suspension Squeaks on Bumps Bulletin No.: j06-03-09-005 Date: June 08, 2006 TECHNICAL Subject: Squawk/Squeak Type Noise From Rear Suspension While Driving Over Bumps At Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > j06-03-09-005 > Jun > 06 > Suspension - Rear Suspension Squeaks on Bumps > Page 11366 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Control Arm Bushing: All Technical Service Bulletins Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Control Arm Bushing: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11376 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11377 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11378 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11379 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11380 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11381 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11382 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > j06-03-09-005 > Jun > 06 > Suspension - Rear Suspension Squeaks on Bumps Control Arm Bushing: All Technical Service Bulletins Suspension - Rear Suspension Squeaks on Bumps Bulletin No.: j06-03-09-005 Date: June 08, 2006 TECHNICAL Subject: Squawk/Squeak Type Noise From Rear Suspension While Driving Over Bumps At Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > j06-03-09-005 > Jun > 06 > Suspension - Rear Suspension Squeaks on Bumps > Page 11387 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension Lower Control Arm Bushings Replacement ^ Tools Required J 41211 Front Control Arm Bushing Set Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the lower control arm. 3. Wrap the control arm with a shop towel and place it in a vise. 4. Important: Note the depth and orientation of the old bushing before removal. Using the J 41211, pull the control arm bushing through the control arm. 5. Disassemble the tools and remove the bushing. Installation Procedure 1. Place the NEW bushing to the tapered side of the control arm. 2. Using the J 41211 , pull the control arm bushing through the opposite direction of the control arm. 3. Install the bushing to the same depth and orientation as noted during removal. 4. Remove the J 41211 from the control arm. 5. Install the control arm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 11390 Control Arm Bushing: Service and Repair Rear Suspension Control Arm Bushing Replacement ^ Tools Required J 44570 Bushing Remover/Installer Kit Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the rear wheels. 3. Place 2 screw type jack stands under both ends of the rear axle. 4. Remove the rear brake hose bracket attaching nuts from the body. 5. Detach the rear brake hose brackets from the body allowing the lines to hang free. 6. Remove the lower shock bolts. Important: Do not kink the brake pipes while lowering the axle. 7. Lower the jacks in order to remove the coil springs. 8. Temporarily re-install the lower shock bolts to support the axle. 9. Remove the bushing bracket to body bolts from both ends of the rear axle. 10. Using the jack stands, raise the rear of the axle until the bushing brackets pivot away from the body. 11. Remove the axle bushing through bolts and remove the bushing brackets. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 11391 Important: Note the depth and orientation of the old bushing before removal. 12. Using the J 44570, install the J 44570-1 (2) with the lip between the axle sleeve and bushing flange. It may require tapping with a hammer to fully seat the tool. 13. Insert J 44570-3 (1) through the J 44570-1 (2) and the axle bushing. 14. Install the washer and nut by hand, tightening until the tool is snug. 15. Using a hammer, drive the bushing from the axle sleeve. 16. Disassemble the tool and remove the bushing. Installation Procedure Important: The axle bushings must be installed in the correct orientation as shown. 1. Slide the new bushings into the axle sleeve in the same orientation noted during removal. Make sure the rubber end (1) is facing inboard and the largest void (2) is in line with the wheel hub center (3). 2. Place the J 44570-1 (2) onto the bushing. Make sure the bushing is still oriented correctly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 11392 3. Insert the J 44570-3 (3) through the J 44570-1 (2) and the axle bushing. 4. Install the J 44570-2 (1) bearing, washer, and nut. 5. Pull the bushing into the axle sleeve by holding the hex end of the threaded shaft while turning the nut. 6. Disassemble and remove the bushing installation tool from the axle. 7. Install the axle brackets to the axle bushings with the alignment slot on the outboard side. Important: The axle bushing through bolts must be installed with the bolt head facing inboard. 8. Loosely install the bushing bolts, park brake cable brackets and nuts. 9. Using the jack stands, lower the rear of the axle until the bushing brackets contact the body. 10. Hand tighten the axle bracket to body bolts just enough to hold the brackets flush to the body. Important: The axle through bolts must be tightened with the axle at the correct trim height and prior to torquing the axle bracket to body bolts. 11. Using the jack stands, raise the axle to the proper trim height specification by measuring the vertical distance between the bottom edge of the upper spring seat and the bottom of the notch in the lower spring seat. Notice: Refer to Fastener Notice in Service Precautions. 12. Tighten the axle bushing through bolts. ^ Tighten the bolts to 90 Nm (66 ft. lbs.) +60 degrees. 13. Insert two 12 mm diameter pins through the axle brackets into the underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 11393 14. Align the left side axle bracket and snug down the bolts. 15. Align the right side axle bracket and snug down the bolts. 16. Tighten all the bracket to body bolts. ^ Tighten the bolts to 90 Nm (66 ft. lbs.) +30 degrees. 17. With the axle supported by the jack stands, remove the lower shock bolts. 18. Lower the jacks in order to install the coil springs. 19. Install the coil springs, making sure the colored tag is facing the rear of the vehicle. 20. Raise the jacks until the springs are slightly compressed in order to install the lower shock bolts. ^ Tighten the lower bolts to 110 Nm (81 ft. lbs.). 21. Remove the jack stands. 22. Reposition the rear brake hose brackets to the body. 23. Install the brake hose bracket attaching nuts. 24. Install the rear wheels. 25. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available Front Steering Knuckle: Technical Service Bulletins Steering - Competition Steering Knuckles Available Bulletin No.: 06-03-08-001D Date: September 27, 2006 INFORMATION Subject: Availability of Steering Knuckles for Competitive Driving Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2004-2007 Saturn ION, ION Redline Supercede: This bulletin is being revised to add a statement in the Alternate Steering Knuckles section. Please discard Corporate Bulletin Number 06-03-08-001C (Section 03 - Suspension). Alternate Steering Knuckles This is to advise owners who intend to use their vehicles for competitive driving, of the availability of alternate steering knuckles, and to provide recommended alignment specifications for those owners who use their vehicles for competitive driving. These steering knuckles are available through GM service parts and are suggested for use on the Cobalt (Pursuit)/ION Redline. Refer to the Parts Information below for ordering instructions. (This steering knuckle may also be installed and the alignment specifications used, at the customer's discretion, for non-competition purposes.) Replacement Procedure Service replacement instructions can be found in SI (Steering Knuckle Replacement). Alignment Settings The alignment following settings provide for even tire wear in competitive driving. Please use the alignment specifications shown for competitive driving only. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available > Page 11398 Parts Information Warranty Information The above modifications are considered to be a customer option and should be performed at the customer's expense. Prior to using your vehicle for competitive driving, refer to your vehicle warranty book or General Motors dealership for information on the General Motors new vehicle factory warranty, and how competitive driving may effect your warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Competition Steering Knuckles Available > Page 11399 Front Steering Knuckle: Technical Service Bulletins Steering - Revised Tie Rod to Steering Knuckle Torque Bulletin No.: 05-03-08-017 Date: December 06, 2005 SERVICE MANUAL UPDATE Subject: Revised Steering Linkage Outer Tie Rod-to-Steering Knuckle Nut Tightening Specification Models: 2005 Chevrolet Cobalt, Equinox 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION, VUE This bulletin is being issued to revise the steering linkage outer tie rod-to-steering knuckle nut tightening specification in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Revised Torque TSB # 05-03-08-017 Dated 12/06/2005 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11400 Front Steering Knuckle: Service and Repair The content of this article reflects the changes identified in TSB Bulletin No. #05-03-08-017 dated December 06, 2005. SUBJECT: Steering Linkage Outer Tie Rod-to-Steering Knuckle Nut Torque Revised Torque TSB # 05-03-08-017 Dated 12/06/2005 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11401 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 11402 Steering Knuckle Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bar Bracket > Component Information > Technical Service Bulletins > Suspension - Alternate Anti-Sway Bar Clamp Procedure Stabilizer Bar Bracket: Technical Service Bulletins Suspension - Alternate Anti-Sway Bar Clamp Procedure Bulletin No.: 07-03-08-007 Date: September 28, 2007 INFORMATION Subject: Alternate Anti-Sway Bar Clamp Service Procedure Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Attention: This procedure is only to be performed as a customer pay. Front Sway Bar Mounting Clamp Service Procedure This is to inform dealers of an optional service procedure for front sway bar mounting clamps that is only to be performed at the owner's expense. This procedure requires the removal of the existing engine cradle and sway bar mounting clamps. These parts should be replaced with the parts listed in the table under Parts Information. Replacement Procedure The following service replacement instructions can be found in SI. Remove the vehicle frame and replace with the part number listed below. Install the new anti-sway bar clamps. Sway Bar Insulator Removal (FE1/FE3) Sway Bar Insulator Removal (FE5) Frame Replacement Parts Information Warranty Information The above modifications are considered to be a customer option and should be performed at the customer's expense. Should your vehicle be used for racing or other competitive driving, refer to your vehicle warranty book or your General Motors dealership for information on the General Motors New Vehicle Limited Warranty and how racing and competitive driving may affect your warranty. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bar Bracket > Component Information > Technical Service Bulletins > Suspension - Alternate Anti-Sway Bar Clamp Procedure > Page 11408 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the front wheels. 3. Remove the stabilizer shaft mounting clamp bolts and clamps from both sides of the vehicle. 4. Remove the bushings from the stabilizer shaft. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Page 11412 1. Install the stabilizer bushings on the stabilizer shaft with the cut line facing rearward. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft clamps and bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the front wheels. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Stabilizer Link: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11421 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11422 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11423 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11424 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11425 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11426 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11427 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Stabilizer Link: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11433 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11434 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11435 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11436 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11437 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11438 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11439 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 11440 Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the front wheel. 3. Disconnect the stabilizer link from the stabilizer shaft. 4. Disconnect the stabilizer link from the strut assembly and remove from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 11441 1. Notice: Refer to Fastener Notice in Service Precautions. Connect the stabilizer link to the strut assembly. ^ Tighten the stabilizer link nut to 65 Nm (48 ft. lbs.). 2. Connect the stabilizer link to the stabilizer shaft. ^ Tighten the stabilizer link nut to 80 Nm (59 ft. lbs.). 3. Install the front wheel. 4. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Front Strut / Shock Tower: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11451 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11452 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11453 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11454 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11455 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11456 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11457 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Front Strut / Shock Tower: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11463 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11464 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11465 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11466 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11467 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11468 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11469 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11470 Front Strut / Shock Tower: By Symptom Technical Service Bulletin # 04-03-08-006E Date: 101101 Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11471 sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11472 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11473 Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11474 Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11475 Warranty Information #5 Condition #6 (FE1 Suspension Only) Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11476 Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11477 Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Technical Service Bulletin # 04-03-08-006E Date: 101101 Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11478 Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11479 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11480 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11481 Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11482 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11483 If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11484 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 11485 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Replacement Tools Required * J 24319-B Steering Linkage and Tie Rod Puller * J 43631 Ball Joint Remover Removal Procedure 1. With the wheels in the straight ahead position, remove the key from the ignition switch. 2. Secure the cooling module to the upper body structure. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the front wheels from the vehicle. 5. Remove the left and right splash shields. 6. Remove the front transaxle mount to cradle through bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11490 7. Remove the rear transaxle mount to frame bolts. 8. Remove both stabilizer link to stabilizer shaft nuts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11491 9. Remove both tie rod to steering knuckle nuts. 10. Use the J 24319-B to separate the outer tie rods from the steering knuckles. 11. Remove the intermediate steering shaft to steering gear pinch bolt and discard. Important: DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur. 12. Disconnect the intermediate steering shaft from the steering gear. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11492 13. Remove both lower control arm ball stud to steering knuckle pinch bolts. Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result. 14. Lower the lower control arms in order to disengage the steering knuckle. If necessary, use the J 43631. 15. Mark the frame to body position with a paint pen or permanent marker. 16. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame. 17. Use two 2 x 4's between the lift table and the frame and lift the table to the frame. 18. Slowly remove the frame bolts using the following sequence: 1. Remove the front frame bolts. 2. Partially unscrew the rear frame bolts exposing 25.4 mm (1.5 in) of bolt shank. 19. Slowly lower the lift table to the floor. 20. Continue with the following steps when replacing the frame: 1. Remove the steering gear from the frame. 2. Remove the stabilizer bar from the frame. 3. Remove the lower control arms from the frame. 4. Remove the radiator brackets from the frame. Installation Procedure 1. If replacing the frame, perform the following steps: 1. Install the radiator brackets to the frame. 2. Install the lower control arms to the frame. 3. Install the stabilizer bar to the frame. 4. Install the steering gear to the frame. 2. With the frame on the lift table, raise the frame to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11493 3. Hand start all the frame bolts while aligning the frame to the paint marks. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the frame bolts. Tighten the bolts to 100 N.m plus 180 degrees (74 lb ft) plus 180 degrees. 5. Lower and remove the hydraulic table. 6. Connect the lower control arm to the steering knuckle. Important: The torque sequence must be followed in the order that is listed. 7. Install the ball joint pinch bolt and nut. 1. First Pass: Tighten the nut to 50 N.m (37 lb ft). 2. Reverse nut 3/4 turn 3. Second Pass: Tighten the nut to 50 N.m (37 lb ft) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11494 Important: The front and rear transmission mounts must be allowed to settle with the through bolts loosened. 8. Hand start the front transaxle mount through bolt. 9. Loosen the rear transmission mount through bolt. 10. Tighten the rear transaxle mount to frame bolts. Tighten the rear bolts to 50 N.m (37 lb ft). 11. Tighten the front and rear transaxle mount through bolts in the following order. 1. Tighten the rear bolt to 100 N.m (74 lb ft). 2. Tighten the front bolt to 100 N.m (74 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 11495 12. Install the outer tie rods to the steering knuckles. 13. Install the new outer tie rod to the knuckle nuts. Tighten the nuts to 20 N.m (15 lb ft) plus 180 degrees. 14. Connect the stabilizer links to the stabilizer shaft. 15. Connect the intermediate shaft to the steering gear. 16. Install a new intermediate shaft pinch bolt. Tighten the bolt to 25 N.m (18 lb ft). 17. Install the left and right splash shields. 18. Install the front wheels. 19. Lower the vehicle. 20. Road test the vehicle in order to test for the following conditions: * Steering leads or pulls-Refer to Measuring Wheel Alignment in Wheel Alignment. * Abnormal powertrain noise or vibration at idle - Refer to Checking Frame Alignment in Frame and Underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension Strut, Strut Component and/or Spring Replacement ^ Tools Required J 45400 Strut Spring Compressor Disassembly Procedure 1. Remove the strut from the vehicle. 2. Install the strut (2) in the J 45400 (1). 3. Important: The spring is compressed when the strut moves freely. Turn the spring compressor forcing screw until the coil spring is compressed. 4. Loosen the compressor forcing screw until the upper strut mount and coil spring may be removed. 5. Use a 45 TORX socket in order to hold the strut shaft. Use a strut rod socket or equivalent to remove the upper strut mount nut. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 11500 6. Remove the upper strut mount and the coil spring from the J 45400. 7. Remove the strut (2) from the J 45400. Assembly Procedure 1. Install the coil spring and upper strut mount to the J 45400. 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the strut to the coil spring and upper strut mount. 4. Loosely install the strut retaining nut. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 11501 5. Notice: Refer to Fastener Notice in Service Precautions. Use a 45 TORX socket in order to hold the strut shaft. Use a strut rod socket or equivalent to Install the upper strut mount nut. ^ Tighten the strut mount nut to 75 Nm (55 ft. lbs.). 6. Remove the strut from the J 45400. 7. Install the strut to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 11502 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring Replacement Coil Spring Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Support the rear axle with tall jack stands near each rear shock absorber. 3. Remove the U-clips from the rear brake hose brackets at the rear axle. 4. Remove the lower shock bolts. 5. Using the tall jack stands, slowly lower the rear axle in order to remove tension from the rear springs. 6. Remove the spring. 7. Remove the upper spring seat/jounce bumper from the spring, while leaving the lower spring seat on the axle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 11503 Important: The rear springs are indexed with the colored tag toward the rear of the vehicle. No up/down or side to side orientation is required. 1. Install the upper spring seat/jounce bumper on the spring. 2. Install the spring with the spring tag toward the rear of the vehicle, making sure the lower coil is seated into the lower spring seat. 3. Using the jack stands, raise the rear axle in order to compress the rear springs. 4. Install the lower shock absorber bolts. 5. Reposition the rear brake hoses in the axle brackets. 6. Install the U-clips to secure the brake hoses. 7. Lower the vehicle. Coil Spring Insulators Replacement Coil Spring Insulators Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 11504 2. Remove the rear spring. 3. Remove the coil spring insulator from the rear axle assembly. Installation Procedure 1. Install the coil spring insulator to the rear axle assembly. 2. Install the rear spring, taking care to properly seat the spring to the insulator. 3. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Suspension Strut / Shock Absorber: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11513 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11514 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11515 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11516 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11517 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11518 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 11519 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11525 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11526 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11527 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11528 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11529 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11530 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 11531 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-08-002C > Oct > 09 > Suspension Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-08-002C > Oct > 09 > Suspension Shock Absorber/Strut Leakage Information > Page 11536 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 11542 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 11548 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Strut Assembly Replacement Strut Assembly Replacement Removal Procedure 1. Remove the strut upper mounting nuts. 2. Important: Lift the vehicle using ONLY a frame-contact vehicle lift. Do NOT lift the vehicle using a suspension-contact vehicle lift. Raise and support the vehicle. Refer to Vehicle Lifting 3. Remove the tire and wheel. 4. Disconnect the stabilizer shaft link from the strut assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11551 5. Remove the strut lower bolts, nuts and antilock brake system (ABS) wiring bracket, if equipped. 6. Remove the strut. Installation Procedure 1. Install the strut. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the strut upper mounting nuts. ^ Tighten the nuts to 20 Nm (15 ft. lbs.). 3. Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if: ^ The fastener and its counterpart are clean and free from rust. ^ The fastener develops 3 Nm (27 inch lbs.) of torque/drag against its counterpart prior to the fastener seating. If the fastener does not meet these criteria, REPLACE the fastener. Install the strut lower bolts, nuts and ABS wiring bracket, if equipped. ^ Tighten the strut lower nuts to 120 Nm (89 ft. lbs.). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11552 4. Connect the stabilizer shaft link to the strut assembly. ^ Tighten the stabilizer shaft link nut to 65 Nm (48 ft. lbs.). 5. Install the tire and wheel. 6. Lower the vehicle. 7. Align the front wheels. Strut, Strut Component and/or Spring Replacement Strut, Strut Component and/or Spring Replacement ^ Tools Required J 45400 Strut Spring Compressor Disassembly Procedure 1. Remove the strut from the vehicle. 2. Install the strut (2) in the J 45400 (1). 3. Important: The spring is compressed when the strut moves freely. Turn the spring compressor forcing screw until the coil spring is compressed. 4. Loosen the compressor forcing screw until the upper strut mount and coil spring may be removed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11553 5. Use a 45 TORX socket in order to hold the strut shaft. Use a strut rod socket or equivalent to remove the upper strut mount nut. 6. Remove the upper strut mount and the coil spring from the J 45400. 7. Remove the strut (2) from the J 45400. Assembly Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11554 1. Install the coil spring and upper strut mount to the J 45400. 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the strut to the coil spring and upper strut mount. 4. Loosely install the strut retaining nut. 5. Notice: Refer to Fastener Notice in Service Precautions. Use a 45 TORX socket in order to hold the strut shaft. Use a strut rod socket or equivalent to Install the upper strut mount nut. ^ Tighten the strut mount nut to 75 Nm (55 ft. lbs.). 6. Remove the strut from the J 45400. 7. Install the strut to the vehicle. Suspension Strut Disposal Suspension Strut Disposal Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11555 Caution: Use the proper eye protection when drilling to prevent metal chips from causing physical injury. 1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil. 3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down. 5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11556 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the wheel. 3. Support the rear axle with a tall jack stand near the shock absorber. Shock Absorber 4. Remove the upper and lower shock bolts. 5. Remove the shock from the vehicle. Installation Procedure 1. Position the shock absorber to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11557 Shock Absorber Notice: Refer to Fastener Notice in Service Precautions. 2. Install NEW upper and lower shock bolts. ^ Tighten the upper bolt to 90 Nm (66 ft. lbs.). ^ Tighten the lower bolt to 110 Nm (81 ft. lbs.). 3. Remove the jack stand. 4. Install the wheel. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11558 shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair Suspension Travel Bumper: Service and Repair Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Lower the rear axle in order to gain access to the top portion of the rear springs. 3. Remove the upper spring seat/jounce bumper from the spring, while leaving the lower spring seat on the axle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Page 11562 Important: The rear springs are indexed with the colored tag toward the rear of the vehicle. No up/down or side to side orientation is required. 1. Install the upper spring seat/jounce bumper on the spring. 2. Raise the rear axle in order to seat rear spring. 3. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Wheel Bearing/Hub Assembly Mounting Bolts ...................................................................................................................................... 115 Nm (85 ft. lbs.) Rear Wheel Bearing/Hub Assembly Mounting Nuts ...................................................................................................................... 45 Nm +30° (33 ft. lbs. + 30°) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 11566 Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11569 Wheel Bearing/Hub Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11570 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Wheel Bearing/Hub Replacement - Rear (Disc Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the rear brake caliper and bracket as an assembly, and remove the rear brake rotor. 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the wheel bearing/hub assembly mounting nuts. 6. Remove the wheel bearing/hub assembly and the disc brake backing plate from the rear axle assembly. Installation Procedure 1. Install the wheel bearing/hub assembly and the brake backing plate to the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11571 3. Connect the electrical connector to the wheel speed sensor. 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Drum Brake Wheel Bearing/Hub Replacement - Rear (Drum Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the plug from the drum brake actuator access hole in the backing plate. Using the access hole, install a support (1) for the brake backing plate. 5. Disconnect the electrical connector (2) from the wheel speed sensor, if equipped with ABS. 6. Remove the wheel bearing/hub assembly mounting nuts (3). 7. Remove the wheel bearing/hub assembly from the rear axle assembly and brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11572 1. Install the wheel bearing/hub assembly to the brake backing plate and the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts (3) to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. 3. Connect the electrical connector (2) to the wheel speed sensor, if equipped with ABS. 4. Remove the support (1) from the brake backing plate. 5. Install the plug to the drum brake actuator access hole in the backing plate. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Nut ...................................................................................................................................... ................................................. 110 Nm (81 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 11581 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Automotive Lift And Floor Jack Contact Points AUTOMOTIVE LIFT AND FLOOR JACK CONTACT POINTS VEHICLE LIFTING-FRAME CONTACT LIFT Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads 6.69 in (170 mm) from the front pinchweld flanges. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads 2.17 in (55 mm) from the rear pinchweld flanges. VEHICLE JACKING Under the Center of the Rear Suspension Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension. SUPPORTING THE VEHICLE WITH JACKSTANDS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 11582 IMPORTANT: Place jackstands ONLY under strong and stable vehicle structures. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11597 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11611 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11616 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11617 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11618 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11619 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11620 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11621 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11622 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11623 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11624 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11625 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 11626 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting Tires: Service and Repair Tire Mounting and Dismounting Tire Mounting and Dismounting Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Deflate the tire completely. Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 2. Use the tire changer in order to remove the tire from the wheel. Important: Rim-clamp European-type tire changers are recommended. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. 4. Apply an approved Lubricant to the tire bead and the wheel rim. Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 5. Use the tire changer in order to install the tire to the wheel. 6. Inflate the tire to the proper air pressure. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting > Page 11629 Tires: Service and Repair Tire Repair Tire Repair Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire Mounting and Dismounting > Page 11630 Tires: Service and Repair Tire Rotation Tire Rotation Rotate the tire and wheel assemblies at frequent intervals to equalize wear. In addition to scheduled rotation, rotate the tire and wheel assembly whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then set the tire pressure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11639 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11640 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11641 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 11646 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11651 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11652 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11653 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11659 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11660 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11661 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 11666 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11671 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11672 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM Wheels: All Technical Service Bulletins Wheels/Tires - 18 Inch Wheels Available Through GM INFORMATION Bulletin No.: 05-03-10-011E Date: May 26, 2010 Subject: 18 Inch Accessory Wheels Available Through GM Accessories Models: 2005-2007 Chevrolet Cobalt SS Supercharged 2006-2008 Chevrolet Cobalt SS (2 Door Coupe and 4 Door Sedan - Excludes Turbocharged) 2007-2011 Chevrolet HHR, HHR Panel (LT Option with 17" Tires (RPO QBV) Only) (Built After VIN Breakpoint 7S541326) 2006 Pontiac Pursuit GT (Canada Only), G4 GT (Mexico Only) 2007-2010 Pontiac G5 GT Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-03-10-011D (Section 03 - Suspension). The purpose of this bulletin is to provide a reference guide for the technician to upgrade a vehicle from factory wheel and tires to 18" wheels and tires, which are available through GM Accessories. This guide will cover tires, wheels, vehicle modifications, and warranty information. Tires GM offers one tire, the Pirelli P-ZERO ROSSO 215/45R18, to be used in conjunction with the 18" accessory wheels. The Pirelli tire has a Tire Performance Criteria (TPC) spec of #1255, which meets or exceeds all federal safety guidelines. Wheels Center Cap Notice Attempting to "hammer on" the caps may result in damage to the cap. Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is by hand. As an alternate, use a non-metallic object to push the center cap into place. Wheel (Lug) Nuts Caution: Incorrect wheel nuts or improperly tightened wheel nuts may cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be tightened to 140 Nm (100 lb ft) using the tightening sequence illustrated above. The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11677 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11678 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11679 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11684 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11685 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11686 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 11691 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11696 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11697 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11698 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11708 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11709 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11710 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 11715 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11720 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11721 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM Wheels: All Technical Service Bulletins Wheels/Tires - 18 Inch Wheels Available Through GM INFORMATION Bulletin No.: 05-03-10-011E Date: May 26, 2010 Subject: 18 Inch Accessory Wheels Available Through GM Accessories Models: 2005-2007 Chevrolet Cobalt SS Supercharged 2006-2008 Chevrolet Cobalt SS (2 Door Coupe and 4 Door Sedan - Excludes Turbocharged) 2007-2011 Chevrolet HHR, HHR Panel (LT Option with 17" Tires (RPO QBV) Only) (Built After VIN Breakpoint 7S541326) 2006 Pontiac Pursuit GT (Canada Only), G4 GT (Mexico Only) 2007-2010 Pontiac G5 GT Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-03-10-011D (Section 03 - Suspension). The purpose of this bulletin is to provide a reference guide for the technician to upgrade a vehicle from factory wheel and tires to 18" wheels and tires, which are available through GM Accessories. This guide will cover tires, wheels, vehicle modifications, and warranty information. Tires GM offers one tire, the Pirelli P-ZERO ROSSO 215/45R18, to be used in conjunction with the 18" accessory wheels. The Pirelli tire has a Tire Performance Criteria (TPC) spec of #1255, which meets or exceeds all federal safety guidelines. Wheels Center Cap Notice Attempting to "hammer on" the caps may result in damage to the cap. Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is by hand. As an alternate, use a non-metallic object to push the center cap into place. Wheel (Lug) Nuts Caution: Incorrect wheel nuts or improperly tightened wheel nuts may cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be tightened to 140 Nm (100 lb ft) using the tightening sequence illustrated above. The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11726 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11727 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-03-10-011E > May > 10 > Wheels/Tires - 18 Inch Wheels Available Through GM > Page 11728 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 11735 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Wheel Bearing/Hub Assembly Mounting Bolts ...................................................................................................................................... 115 Nm (85 ft. lbs.) Rear Wheel Bearing/Hub Assembly Mounting Nuts ...................................................................................................................... 45 Nm +30° (33 ft. lbs. + 30°) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 11739 Steps 1 - 7 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11742 Wheel Bearing/Hub Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11743 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Wheel Bearing/Hub Replacement - Rear (Disc Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the rear brake caliper and bracket as an assembly, and remove the rear brake rotor. 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the wheel bearing/hub assembly mounting nuts. 6. Remove the wheel bearing/hub assembly and the disc brake backing plate from the rear axle assembly. Installation Procedure 1. Install the wheel bearing/hub assembly and the brake backing plate to the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11744 3. Connect the electrical connector to the wheel speed sensor. 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Drum Brake Wheel Bearing/Hub Replacement - Rear (Drum Brake) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the plug from the drum brake actuator access hole in the backing plate. Using the access hole, install a support (1) for the brake backing plate. 5. Disconnect the electrical connector (2) from the wheel speed sensor, if equipped with ABS. 6. Remove the wheel bearing/hub assembly mounting nuts (3). 7. Remove the wheel bearing/hub assembly from the rear axle assembly and brake backing plate. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 11745 1. Install the wheel bearing/hub assembly to the brake backing plate and the rear axle assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel bearing/hub assembly mounting nuts (3) to the axle assembly. Tighten the nuts evenly, in a cross-pattern. ^ Tighten the nuts to 45 Nm (33 ft. lbs.) plus 30 degrees. 3. Connect the electrical connector (2) to the wheel speed sensor, if equipped with ABS. 4. Remove the support (1) from the brake backing plate. 5. Install the plug to the drum brake actuator access hole in the backing plate. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise Wheel Cover: Customer Interest Tires/Wheels - Wheel Squeak Noise TECHNICAL Bulletin No.: 05-03-10-006D Date: June 02, 2010 Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with 15-Inch Wheel Covers Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 05-03-10-006C (Section 03 - Suspension). Condition Some customers may comment on a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h [0-15 mph]). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction Install insulator tape on the backside of all four wheel covers. Use the following procedure: Chevrolet Cobalt/Pontiac G5 Pontiac Pursuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise > Page 11754 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol (using a clean, lint-free, non-abrasive cloth) at the insulator locations. Refer to the illustrations above. 5. Cut forty 7 mm (0.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside at the outer most edge as shown in the illustrations above. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be 10 insulators placed on each wheel cover. Important Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information *To obtain this product, check your dealer's auto body shop - they may already have this tape. You may also contact the 3M(R) Automotive Aftermarket Helpline at 1-877-666-2277 and follow the menu options to locate a store near you where it can be purchased. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 05-03-10-006D > Jun > 10 > Tires/Wheels Wheel Squeak Noise Wheel Cover: All Technical Service Bulletins Tires/Wheels - Wheel Squeak Noise TECHNICAL Bulletin No.: 05-03-10-006D Date: June 02, 2010 Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with 15-Inch Wheel Covers Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 05-03-10-006C (Section 03 - Suspension). Condition Some customers may comment on a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h [0-15 mph]). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction Install insulator tape on the backside of all four wheel covers. Use the following procedure: Chevrolet Cobalt/Pontiac G5 Pontiac Pursuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 05-03-10-006D > Jun > 10 > Tires/Wheels Wheel Squeak Noise > Page 11760 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol (using a clean, lint-free, non-abrasive cloth) at the insulator locations. Refer to the illustrations above. 5. Cut forty 7 mm (0.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside at the outer most edge as shown in the illustrations above. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be 10 insulators placed on each wheel cover. Important Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information *To obtain this product, check your dealer's auto body shop - they may already have this tape. You may also contact the 3M(R) Automotive Aftermarket Helpline at 1-877-666-2277 and follow the menu options to locate a store near you where it can be purchased. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Nut ...................................................................................................................................... ................................................. 110 Nm (81 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 11773 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 11779 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 11780 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 11781 Wheel Nut Torque Sequence Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension (4-Stud Pattern) Wheel Stud Replacement (4-Stud Pattern) ^ Tools Required J 43631 Ball Joint Remover Notice: Avoid tool contact to the outer constant velocity boot seal when removing the wheel bearing mounting bolts. Failure to observe this notice may result in damage to the CV boot. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. 4. Inspect the head of the wheel stud to be replaced, to determine if the stud is an original, round-head, or a service replacement, D-shape head. Important: It will be necessary to cut off a portion of an original, round-head wheel stud in order to provide clearance to remove the stud from the wheel bearing hub. 5. If an original, round-head wheel stud is to be replaced, then a portion of the stud must be cut off, so that the remainder of the stud will be approximately 10 mm (0.39 inch) long from the face of the bearing hub flange. 6. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 7. Using the J 43631 , release the wheel stud from the bearing hub. If a portion of the stud was cut off, remove and discard the stud. 8. Loosen the 3 wheel bearing/hub assembly mounting bolts evenly, until there is approximately 7 mm (1/4 inch) of clearance between the seat of the bearing assembly and the steering knuckle. This will be necessary for removing and installing a service replacement D-shape head stud. 9. If the stud being replaced was a D-shape head, remove and discard the stud. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11784 Important: The replacement front wheel stud has a D-shape head to provide clearance for installation. 1. With the bearing hub still in position, install the NEW service replacement stud into the bearing/hub assembly. Notice: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the wheel bearing/hub assembly mounting bolts evenly to draw the bearing assembly back to the steering knuckle, then tighten the bolts to specifications. ^ Tighten the bolts to 115 Nm (85 ft. lbs.). 3. Add enough washers (1) in order to draw the stud into the hub. 4. Install the wheel nut (2) with the flat side against the washers. 5. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 6. Remove the wheel nut and the washers. 7. Install the brake rotor, and install the brake caliper and bracket as an assembly. 8. Install the tire and wheel assembly. 9. Lower the vehicle. (5-Stud Pattern) Wheel Stud Replacement (5-Stud Pattern) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11785 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Without disconnecting the hydraulic brake flex hose, remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. 4. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 5. Using the J 43631 , release the wheel stud from the bearing hub and discard the stud. Installation Procedure 1. With the bearing hub still in position, install the NEW stud into the bearing/hub assembly. 2. Add enough washers (1) in order to draw the stud into the hub. 3. Install the wheel nut (2) with the flat side against the washers. 4. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut and the washers. 6. Install the brake rotor, and install the brake caliper and bracket as an assembly. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11786 Wheel Fastener: Service and Repair Rear Suspension Disc Brake Wheel Stud Replacement (Disc Brake) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake rotor. 4. Using the J 43631 , remove and discard the wheel stud. Installation Procedure 1. Install the NEW wheel stud into the wheel bearing hub. 2. Add enough washers (3) in order to draw the stud into the hub. 3. Install the wheel nut (1) with the flat side against the washers. 4. Tighten the wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut (1) and the washers (3). 6. Install the brake rotor. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Drum Brake Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11787 Wheel Stud Replacement (Drum Brake) ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Using the J 43631 , remove and discard the wheel stud. Installation Procedure 1. Install the NEW wheel stud into the wheel bearing hub. 2. Add enough washers (1) in order to draw the stud into the hub. 3. Install the wheel nut (2) with the flat side against the washers. 4. Tighten the wheel nut until the head of the wheel stud is fully seated against the back of the bearing hub flange. 5. Remove the wheel nut and the washers. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Interior HVAC Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Temperature Actuator Air Temperature Actuator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Temperature Actuator > Page 11795 Mode Actuator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Temperature Actuator > Page 11796 Recirculation Actuator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Air Door Actuator / Motor: Service and Repair Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuse labeled HVAC CTRL (BATT). 2. Remove the steering column filler panel. 3. Disconnect the air temperature actuator electrical connector. 4. Remove the air temperature actuator screws. 5. Remove the air temperature actuator. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 11799 1. Install the air temperature actuator. IMPORTANT: The key should be in the OFF position when connecting the electrical connectors to ensure proper calibration. 2. Install the air temperature actuator screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2.2 N.m (19 lb in). 3. Install the air temperature actuator electrical connector. 4. Install the steering column filler panel. 5. Install the fuse labeled HVAC CTRL (BATT). 6. Start the engine and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control assembly while the HVAC control assembly and actuators are calibrating. If interrupted improper HVAC performance will result. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 11800 Air Door Actuator / Motor: Service and Repair Mode Actuator MODE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air temperature actuator. 2. Disconnect the mode actuator electrical connector. 3. Remove the mode actuator assembly screws. 4. Remove the mode actuator assembly. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 11801 1. Install the mode actuator assembly. IMPORTANT: The key should be in the OFF position when connecting the electrical connectors to ensure proper calibration. 2. Install the mode actuator assembly screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2.2 N.m (19 lb in). 3. Install the mode actuator electrical connector. 4. Install the air temperature actuator. 5. Start the engine and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control assembly while the HVAC control assembly and actuators are calibrating. If interrupted improper HVAC performance will result. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 11802 Air Door Actuator / Motor: Service and Repair Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuse labeled HVAC CTRL (BATT). 2. Remove the I/P retainer. 3. Disconnect the recirculation actuator electrical connector. 4. Remove the recirculation actuator screw. 5. Remove the recirculation actuator. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 11803 1. Install the recirculation actuator. IMPORTANT: The key should be in the OFF position when connecting the electrical connectors to ensure proper calibration. 2. Install the recirculation actuator screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 2.2 N.m (19 lb in). 3. Install the recirculation electrical connector. 4. Install the I/P retainer. 5. Install the fuse labeled HVAC CTRL (BATT). 6. Start the engine and let run for one minute. IMPORTANT: Do not adjust any controls on the HVAC control assembly while the HVAC control assembly and actuators are calibrating. If interrupted improper HVAC performance will result. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Air Duct: Service and Repair Center AIR OUTLET DUCT REPLACEMENT - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) center trim panel. 2. Remove the center air outlet duct screws and duct. INSTALLATION PROCEDURE 1. Install the center air outlet duct. 2. Install the center air outlet screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the center air outlet duct screws to 2.5 N.m (22 lb in). 3. Install the instrument panel (I/P) center trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11808 Air Duct: Service and Repair Center Floor AIR OUTLET DUCT REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts. 2. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module. INSTALLATION PROCEDURE 1. Align the center floor duct with the HVAC module. 2. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module. 3. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts. 4. Slide the center floor outlet duct down into position in the floor ducts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11809 Air Duct: Service and Repair Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the front seat. 2. Remove the front carpet retainer. 3. Pull the carpet up to access the floor duct. 4. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle. INSTALLATION PROCEDURE 1. Align the floor duct with the center floor outlet duct. 2. Align the floor duct with the floor support beam and snap into place. 3. Reposition the carpet. 4. Install the carpet retainer. 5. Install the front seat. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11810 Air Duct: Service and Repair Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH REMOVAL PROCEDURE 1. Remove the front seat. 2. Remove the front carpet retainer. 3. Remove the front floor console. 4. Pull the carpet up to access the floor duct. 5. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle. INSTALLATION PROCEDURE 1. Align the floor duct with the center floor outlet duct. 2. Align the floor duct with the floor support beam and snap into place. 3. Reposition the carpet. 4. Install the front floor console. 5. Install the carpet retainer. 6. Install the front seat. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11811 Air Duct: Service and Repair Center AIR OUTLET DUCT REPLACEMENT - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) center trim panel. 2. Remove the center air outlet duct screws and duct. INSTALLATION PROCEDURE 1. Install the center air outlet duct. 2. Install the center air outlet screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the center air outlet duct screws to 2.5 N.m (22 lb in). 3. Install the instrument panel (I/P) center trim panel. Center Floor AIR OUTLET DUCT REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11812 1. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts. 2. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module. INSTALLATION PROCEDURE 1. Align the center floor duct with the HVAC module. 2. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module. 3. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts. 4. Slide the center floor outlet duct down into position in the floor ducts. Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the front seat. 2. Remove the front carpet retainer. 3. Pull the carpet up to access the floor duct. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11813 4. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle. INSTALLATION PROCEDURE 1. Align the floor duct with the center floor outlet duct. 2. Align the floor duct with the floor support beam and snap into place. 3. Reposition the carpet. 4. Install the carpet retainer. 5. Install the front seat. Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH REMOVAL PROCEDURE 1. Remove the front seat. 2. Remove the front carpet retainer. 3. Remove the front floor console. 4. Pull the carpet up to access the floor duct. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11814 5. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle. INSTALLATION PROCEDURE 1. Align the floor duct with the center floor outlet duct. 2. Align the floor duct with the floor support beam and snap into place. 3. Reposition the carpet. 4. Install the front floor console. 5. Install the carpet retainer. 6. Install the front seat. Instrument Panel (I/P) - Upper Left AIR OUTLET DUCT REPLACEMENT - INSTRUMENT PANEL (I/P) - UPPER LEFT REMOVAL PROCEDURE 1. Remove the left instrument panel (I/P) trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11815 2. Remove the outer air duct screw and duct. INSTALLATION PROCEDURE 1. Install the outer air duct. 2. Install the outer air duct screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air outlet duct screw to 2.5 N.m (22 lb in). 3. Install the left instrument panel (I/P) trim panel. Instrument Panel (I/P) - Upper Right AIR OUTLET DUCT REPLACEMENT - INSTRUMENT PANEL (I/P) - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the right instrument panel (I/P) trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center > Page 11816 2. Remove the outer air duct screw and duct. INSTALLATION PROCEDURE 1. Install the outer air duct. 2. Install the outer air duct screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the air outlet duct screw to 2.5 N.m (22 lb in). 3. Install the right instrument panel (I/P) trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield Air Register: Service and Repair Defroster Duct - Windshield DEFROSTER DUCT REPLACEMENT - WINDSHIELD REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) retainer. 2. Unsnap the defroster duct from the HVAC module and cross car beam. Bend the cluster wire harness tab on the cross car beam in order to remove the duct. INSTALLATION PROCEDURE 1. Align the defroster duct with the HVAC module and snap into place. 2. If the cluster wire harness tab on the cross car beam was bent during removal, bend the tab back into position. 3. Install the I/P retainer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield > Page 11821 Air Register: Service and Repair Instrument Panel AIR OUTLET REPLACEMENT - INSTRUMENT PANEL REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the screws from the outlet. 3. Remove the outlet from the vehicle. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield > Page 11822 1. Install the outlet to the I/P top panel. 2. Install the screws to the outlet. 3. Tighten the screws. NOTE: Refer to Fastener Notice. Tighten the screws to 2.2 N.m (19 lb in). 4. Install the I/P upper trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield > Page 11823 Air Register: Service and Repair Instrument Panel - Center AIR OUTLET REPLACEMENT - INSTRUMENT PANEL - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the screws from the outlet. 3. Remove the outlet from the vehicle. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield > Page 11824 1. Install the outlet to the I/P top panel. 2. Install the screws to the outlet. 3. Tighten the screws. NOTE: Refer to Fastener Notice. Tighten the screws to 2.2 N.m (19 lb in). 4. Install a new palnut to the air outlet. 5. Install the I/P upper trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Duct - Windshield > Page 11825 Air Register: Service and Repair Side Window AIR OUTLET REPLACEMENT - SIDE WINDOW REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the nut from the side window defog outlet grille. 3. Use a small, flat-bladed tool to release the tabs on the outlet grille. Remove the grille from the I/P top panel. INSTALLATION PROCEDURE 1. Install the side window defog grille to the instrument panel (I/P) upper trim panel. 2. Install a new nut to the outlet grille. IMPORTANT: Always use a new nut for the outlet grille. 3. Check the outlet grille for proper fit and appearance. 4. Install the I/P upper trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11831 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11832 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11833 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11834 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11835 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11836 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11837 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11838 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11839 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11840 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11841 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11842 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11843 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11844 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11845 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11846 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11847 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11848 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11849 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11850 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11851 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11852 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11853 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11854 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11855 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11856 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11857 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11858 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11859 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11860 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11861 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11862 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11863 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11864 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11865 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11866 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11867 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11868 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11869 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11870 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11871 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11872 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11873 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11874 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11875 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11876 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11877 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11878 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11879 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11880 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11881 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11882 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11883 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11884 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11885 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11886 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11887 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11888 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11889 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11890 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11891 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11892 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11893 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11894 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11895 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11896 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11897 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11898 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11899 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11900 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11901 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11902 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11903 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11904 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Interior HVAC Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 11908 Blower Motor Resistor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 11909 Blower Motor Resistor: Service and Repair BLOWER MOTOR RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the blower motor resistor electrical connector. 2. Unsnap the blower motor resistor from the HVAC module and remove. INSTALLATION PROCEDURE 1. Snap the blower motor resistor into the HVAC module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 11910 2. Connect the blower motor electrical connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Blower Motor Switch: Customer Interest A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 11919 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Blower Motor Switch: All Technical Service Bulletins A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 11925 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shifter A/T: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11931 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11932 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11933 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Shifter A/T: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 11938 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 05-07-30-015 > Jun > 05 > A/T - 4T45E Hard to Shift Into Gear Shifter A/T: All Technical Service Bulletins A/T - 4T45E Hard to Shift Into Gear Bulletin No.: 05-07-30-015 Date: June 02, 2005 TECHNICAL Subject: Hard To Shift Or Select Vehicle Gear, Shifter Sticks/Binds/Jams (Replace Shifter Control Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada) with 4T45E Automatic Transaxle (MN5) Condition Some customers may comment that the button on the shifter handle is stuck and will not move. Correction Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. If the park pawl pin does move, refer to normal diagnostics in SI. 1. Set the parking brake. 2. Shift the vehicle into NEUTRAL. 3. Turn and slide down the shift control sleeve (3). 4. Loosen the shift control handle screw (2) with an allen wrench. 5. Remove the shift control handle (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 05-07-30-015 > Jun > 05 > A/T - 4T45E Hard to Shift Into Gear > Page 11943 6. Install the new shift control handle (1) (refer to Parts Information below). Tighten Tighten the shift control handle screw (2) to 10 N.m (88 lb in). 7. Reinstall the shift control sleeve (3) by sliding the sleeve up into place. Ensure that it is locked into place. 8. Test the shift control operation. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11949 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11950 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 11951 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 11956 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 05-07-30-015 > Jun > 05 > A/T - 4T45E Hard to Shift Into Gear > Page 11961 6. Install the new shift control handle (1) (refer to Parts Information below). Tighten Tighten the shift control handle screw (2) to 10 N.m (88 lb in). 7. Reinstall the shift control sleeve (3) by sliding the sleeve up into place. Ensure that it is locked into place. 8. Test the shift control operation. Parts Information Parts are currently available from GMSPO Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations PASSENGER COMPARTMENT AIR FILTER The Access Panel for the Passenger Compartment Air Filter is located in the back of the glove compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 11965 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT REMOVAL PROCEDURE 1. Open the I/P compartment. The access door for the passenger compartment air filter is located behind the glove box. 2. Tilt the I/P compartment door down by squeezing in on each side of the bin until the door stops can be removed from the tracks. 3. Lower the I/P compartment completely. 4. Open the passenger compartment filter door by reaching through the opening in the rear of the I/P compartment and raising the tab until the door can be opened downward. 5. Remove the filter by sliding the filter out of the passenger compartment filter housing. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 11966 IMPORTANT: Make certain that the air flow indicator is pointing down. 1. Install the new filter by sliding the filter into the passenger compartment filter housing. 2. Close the passenger compartment filter door and snap the tab down to latch the door. 3. Raise the I/P compartment door until the door stops contact the frame. Slowly raise the door until the doorstops snap into their tracks. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Cabin Ventilation Grille: Customer Interest A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 11975 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C Water Leaks Onto Passenger Floor/Blower Motor Inop Cabin Ventilation Grille: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 11981 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Page 11982 Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams A/C Compressor Clutch (With RPO Code C67) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 11987 Compressor Clutch: Service and Repair COMPRESSOR CLUTCH ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 37872 Universal Spanner Wrench - J 6083 Snap Ring Pliers REMOVAL PROCEDURE 1. Remove the compressor. 2. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. IMPORTANT: Remove the three adjustable dowels from the J 37872 Universal Spanner Wrench. - Install three 5/16 x 1 inch bolts in place of the dowels. 3. Remove the compressor clutch plate from the compressor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 11988 4. Remove the compressor pulley snap ring using the J 6083. 5. Remove the compressor pulley from the compressor. 6. Remove the compressor clutch coil snap ring using the J 6083. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 11989 7. Remove the compressor clutch coil from the compressor. INSTALLATION PROCEDURE 1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air. 2. Install the compressor clutch coil to the compressor. 3. Install the compressor clutch coil snap ring using the J 6083. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 11990 4. Install the compressor pulley to the compressor. 5. Install the compressor pulley snap ring using the J 6083. 6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate. 7. Install the compressor clutch plate to the compressor. 8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap. IMPORTANT: Make certain that the drive plate does not drag against the pulley when the pulley is rotated. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 11991 9. Install the clutch drive plate bolt. IMPORTANT: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. 10. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the compressor clutch drive plate bolt.Use the J 37872 to hold the compressor clutch plate from turning. Tighten the bolt to 12 N.m (9 lb ft). 11. Install the compressor. 12. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the compressor hose from the condenser. 4. Remove the condenser tube from the condenser. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 11995 5. Remove the condenser bolts. 6. Slide the condenser down to disengage the upper mounting tabs from the radiator. 7. Remove the right and left radiator side baffles. INSTALLATION PROCEDURE 1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 11996 2. Install the right and left radiator side baffles. 3. Slide the condenser up to engage the upper mounting tabs into the radiator brackets. 4. Install the condenser bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 10 N.m (88 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 11997 5. Install the compressor hose and new seal washer to the condenser. Tighten the bolt to 20 N.m (15 lb ft). 6. Install the condenser tube and new seal washer to the condenser. Tighten the bolt to 20 N.m (15 lb ft). 7. Lower the vehicle. 8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Control Assembly: Customer Interest A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 12006 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Control Assembly: All Technical Service Bulletins A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 12012 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns Stabilizer Link: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12018 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12019 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12020 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12021 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12022 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12023 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12024 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12030 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12031 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12032 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12033 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12034 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12035 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 12036 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 12037 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 12038 Control Assembly: Diagrams HVAC Control Module C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 12039 HVAC Control Module C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 12040 HVAC Control Module C3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 12041 Control Assembly: Service and Repair HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P center trim panel. 2. Remove the HVAC control module assembly screws. 3. Remove the HVAC control module assembly. 4. Disconnect the HVAC control module assembly electrical connectors. INSTALLATION PROCEDURE 1. Connect the HVAC control module assembly electrical connectors. 2. Install the HVAC control module assembly. 3. Install the HVAC control module screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 2.2 N.m (19 lb in). 4. Install the I/P center trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair A/C Coupler O-ring: Service and Repair SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 4. Discard the sealing washer. IMPORTANT: DO NOT reuse the sealing washer. INSTALLATION PROCEDURE 1. Inspect the new seal washer for any signs of cracks, cuts, or damage.Do not use a damaged seal washer. IMPORTANT: Flat washer type seals do not require lubrication. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component.The washer must completely bottom against the surface of the fitting. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 12054 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 12055 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 12061 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 12062 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly Evaporator Core: Service and Repair Air Conditioning (A/C) Evaporator and Blower Module Assembly AIR CONDITIONING (A/C) EVAPORATOR AND BLOWER MODULE ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module from the vehicle. See: Housing Assembly HVAC/Service and Repair 2. Remove the heat stakes from the heater core cover using a small chisel and remove the cover. 3. Remove the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12065 4. Remove the heat stakes that secure the lower HVAC case to the HVAC module using a small chisel. 5. Unsnap and open the passenger compartment filter door. 6. Remove the lower HVAC case. 7. Remove the evaporator core. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12066 1. Install the evaporator core into the HVAC module assembly. 2. Install the lower HVAC case. IMPORTANT: Verify that the orifice plate is correctly positioned in the HVAC module. Verify that the lower HVAC case is properly positioned and is fully seated on the HVAC module. Install new screws that will secure the lower HVAC case to the HVAC module. 3. Install the lower HVAC case screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.8 N.m (16 lb in). 4. Close and secure the passenger compartment filter door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12067 5. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. 6. Install the heater core into the HVAC module. 7. Install the heater core cover and the screws. IMPORTANT: Verify that the heater core cover is properly positioned and is fully seated on the HVAC module. Install new screws that secure the heater core cover to the HVAC module. Tighten the screws to 1.8 N.m (16 lb in). 8. Replace the drain tube seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12068 9. Replace the front of dash seal. 10. Inspect and replace the following HVAC module seals if damaged: - The defrost duct seal - The HVAC module to cross car duct seal - The center air outlet duct seal - The center floor air outlet duct seal - The air inlet seal 11. Install the HVAC module in the vehicle. 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using J 39400-A. 14. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12069 Evaporator Core: Service and Repair Evaporator Core Replacement EVAPORATOR CORE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the HVAC module from the vehicle. See: Housing Assembly HVAC/Service and Repair 2. Remove the heater core cover heat stakes with a small chisel. 3. Remove the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12070 4. Unsnap and open the passenger compartment filter door. 5. Remove the lower HVAC case screws. 6. Remove the lower HVAC case. 7. Remove the evaporator core. INSTALLATION PROCEDURE 1. If replacing the evaporator core, add polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant System Capacities. 2. Install new seal washers to the evaporator core fittings. 3. Install the thermal expansion valve (TXV). 4. Install the TXV bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the TXV bolts to 7 N.m (62 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12071 5. Install the foam seals to the evaporator core. 6. Install the evaporator core into the HVAC module assembly. 7. Install the lower HVAC case. IMPORTANT: Make certain that the orifice plate is correctly positioned in the HVAC module. Make certain that the lower HVAC case is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all lower HVAC case screws. 8. Install the lower HVAC case screws. Tighten the screws to 1.8 N.m (15 lb in). 9. Close and secure the passenger compartment filter door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Air Conditioning (A/C) Evaporator and Blower Module Assembly > Page 12072 10. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. 11. Install the heater core into the HVAC module. 12. IMPORTANT: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws. 13. Install the heater core cover screws. Tighten the screws to 1.8 N.m (15 lb in). 14. Install the HVAC module into the vehicle. 15. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings using the J 39400-A. 17. Connect the negative battery cable. 18. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 3. Remove and discard the seal washers. 4. Remove the TXV bolts. 5. Remove the TXV. 6. Remove and discard the seal washers. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 12076 1. Install new seal washers to the evaporator core fittings. 2. Install the TXV. 3. Install the TXV bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 7 N.m (62 lb in). 4. Install new sealing washers on the condenser tube and evaporator hose fittings. 5. Install the condenser tube and evaporator hose to the TXV. 6. Install the TXV nut. Tighten the nut to 20 N.m (15 lb ft). 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 12081 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 12082 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the body control module (BCM) from the vehicle. 2. Remove the front floor console left side extension panel. 3. Pull back the carpet at the bottom of the left instrument panel (I/P) center support bracket and remove the left I/P center support bracket nuts. 4. Remove the left I/P center support bracket. 5. Remove the accelerator control pedal from the front of the dash and position out of the way. 6. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts. 7. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage it from the HVAC module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12085 8. Remove the heater core cover heat stakes with a small chisel. 9. Loosen the nut that is behind the fuel line bracket and remove the stud from the dash panel at the heater hoses. 10. Pull the heater core cover down just enough to clear the locating pins from the HVAC module. Slide the heater core cover rearward until the drain tube clears the front of dash. Slide the heater core cover down, rearward, and to the right to remove. IMPORTANT: Make certain that all of the heater core cover screws are removed before attempting to remove the heater core cover. INSTALLATION PROCEDURE 1. Install a new drain tube seal onto the drain tube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12086 2. Install the heater core cover from the right side. Slide up and forward into position. Align the drain tube with the hole in the front of dash. Raise the heater core cover into position while aligning holes with the locating pins from the HVAC module. IMPORTANT: Spraying the heater core seal and the dashmat with a soap and water mixture will ease installation. 3. Cut the sound insulator at the cowl near the center screw (1) approximately 76 mm (3 in) and fold the sound insulator back to ease in installation of the screw.Ensure the sound insulator is positioned back after the screws are tightened. 4. Install the heater core cover screws. IMPORTANT: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the heater core cover screws to 1.8 N.m (15 lb in). 5. Install the stud into the dash panel at the heater hoses and tighten the nut that is behind the fuel line bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12087 6. Align the center floor duct with the HVAC module. 7. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module. 8. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts. 9. Slide the center floor outlet duct down into position in the floor ducts. 10. Install the accelerator control pedal. 11. Pull back the carpet and place the left center support bracket into position. 12. Install the left center support bracket nuts. Tighten the left center support bracket nuts to 10 N.m (88 lb in). 13. Install the left side front floor console extension panel. 14. Install the BCM to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12088 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED SA9111E Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Place a drain pan under the water pump drain port. 4. Loosen the water pump drain bolt and drain the coolant from the water pump. 5. Close and tighten the water pump drain bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the water pump drain bolt to 10 N.m (88 lb in). 6. Lower the vehicle. 7. Reposition the heater outlet hose clamp at the heater core using SA9111E. 8. Remove the heater outlet hose from the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12089 9. Reposition the heater inlet hose clamp at the heater core using SA9111E. 10. Remove the heater inlet hose from the heater core. 11. Remove the heater core cover. 12. Remove the heater core. INSTALLATION PROCEDURE 1. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 12090 2. Install the heater core into the HVAC module. 3. Install the heater core cover. 4. Install the heater outlet hose to the heater core. 5. Install the hose clamp to secure the hose using SA9111E. 6. Install the heater inlet hose to the heater core. 7. Install the hose clamp to secure the hose using SA9111E. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Remove the surge tank cap. 2. Slide a drain pan under the front of the dashboard under the heater inlet hose. 3. Reposition the heater inlet hose clamp at the heater core using J 38185. 4. Remove the heater inlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 12095 5. Reposition the heater inlet hose clamp at the engine using J 38185. 6. Remove the heater inlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater inlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 12096 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the surge tank cap. CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 2. Place a drain pan under the heater hoses near the front of the dash. 3. Remove the dash panel exterior sound barrier. 4. Reposition the heater outlet hose clamp at the heater core using J 38185. 5. Remove the heater outlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 12097 6. Reposition the hose heater outlet hose clamp at the engine using J 38185. 7. Remove the heater outlet hose from the engine. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the heater core. 2. Reposition the hose clamp to secure the hose using J 38185. 3. Install the heater outlet hose to the engine. 4. Reposition the hose clamp to secure the hose using J 38185. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 6. Remove the drain pan from under the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 12098 7. Install the dash panel exterior sound barrier. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair High Pressure Safety Valve HVAC: Service and Repair COMPRESSOR PRESSURE RELIEF VALVE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the pressure relief valve from the compressor. INSTALLATION PROCEDURE 1. Install the pressure relief valve and seal to the compressor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the compressor pressure relief valve to 7 N.m (62 lb in). 2. Lower the vehicle. 3. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 4. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement Hose/Line HVAC: Technical Service Bulletins A/C - Revised Compressor Hose Assembly Replacement Bulletin No.: 06-01-37-003 Date: March 17, 2006 SERVICE MANUAL UPDATE Subject: Revised Compressor Hose Assembly Replacement (RPO LSJ) Models: 2005-2006 Chevrolet Cobalt with 2.0L Engine (VIN P - RPO LSJ) This bulletin is being issued to revise the Compressor Hose Assembly Replacement (RPO LSJ) procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Compressor Hose Assembly Replacement Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 12106 5. Remove the mounting cover from the charge air cooler pump and position the pump forward. 6. Disconnect the electrical connector from the pressure transducer. 7. Remove the compressor and condenser hose assembly bolt from the compressor. 8. Remove the compressor and condenser hose assembly from the compressor. 9. Remove and discard the sealing washers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 12107 10. Remove the compressor hose from the condenser. 11. Remove and discard the seal washer. Installation Procedure 1. Route the compressor hose to the evaporator hose. 2. Install new sealing washers on the compressor and condenser hose fittings. Refer to Sealing Washer Replacement. 3. Install the A/C compressor and condenser hose assembly to the compressor. Note: Refer to Fastener Notice in Cautions and Notices. 4. Install the A/C compressor and condenser hose assembly bolt. Tighten Tighten the bolt to 20 N.m (15 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 12108 5. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 6. Install the compressor hose and bolt to the condenser. Tighten Tighten the bolt to 20 N.m (15 lb ft). 7. Connect the pressure transducer electrical connector. 8. Install the charge cooler pump. Tighten Tighten the bolts to 10 N.m (88 lb in). 9. Lower the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C - Revised Compressor Hose Assembly Replacement > Page 12109 10. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 11. Install the compressor hose and nut to the evaporator hose. Tighten Tighten the nut to 20 N.m (15 lb ft). 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using the J 39400-A. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube Hose/Line HVAC: Service and Repair Condenser Tube CONDENSER TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the condenser tube bolt and tube from the condenser. 4. Remove and discard the sealing washers. 5. Lower the vehicle. 6. Remove the condenser tube from the frame rail. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12112 7. Remove the condenser tube from the front of dash. 8. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 9. Remove and discard the seal washer. INSTALLATION PROCEDURE 1. Install new sealing washers on the condenser tube and evaporator hose fittings. 2. Install the condenser tube and evaporator hose to the TXV. 3. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12113 Tighten the nut to 20 N.m (15 lb ft). 4. Install the condenser tube to the front of dash. Tighten the nut to 10 N.m (88 lb in). 5. Install the condenser tube to the frame rail. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Install a new seal washer to the condenser tube. 8. Install the condenser tube and bolt to the condenser. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12114 Tighten the bolt to 20 N.m (15 lb ft). 9. Lower the vehicle. 10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12115 Hose/Line HVAC: Service and Repair Compressor Hose Assembly The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-01-37-003 Date: March 17, 2006 SERVICE MANUAL UPDATE Subject: Revised Compressor Hose Assembly Replacement (RPO LSJ) Models: 2005-2006 Chevrolet Cobalt with 2.0L Engine (VIN P - RPO LSJ) Compressor Hose Assembly Replacement Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 5. Remove the mounting cover from the charge air cooler pump and position the pump forward. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12116 6. Disconnect the electrical connector from the pressure transducer. 7. Remove the compressor and condenser hose assembly bolt from the compressor. 8. Remove the compressor and condenser hose assembly from the compressor. 9. Remove and discard the sealing washers. 10. Remove the compressor hose from the condenser. 11. Remove and discard the seal washer. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12117 1. Route the compressor hose to the evaporator hose. 2. Install new sealing washers on the compressor and condenser hose fittings. 3. Install the A/C compressor and condenser hose assembly to the compressor. Note: Refer to Fastener Notice in Cautions and Notices. 4. Install the A/C compressor and condenser hose assembly bolt. Tighten the bolt to 20 N.m (15 lb ft). 5. Install a new seal washer to the compressor hose. 6. Install the compressor hose and bolt to the condenser. Tighten the bolt to 20 N.m (15 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12118 7. Connect the pressure transducer electrical connector. 8. Install the charge cooler pump. Tighten the bolts to 10 N.m (88 lb in). 9. Lower the vehicle. 10. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement. 11. Install the compressor hose and nut to the evaporator hose. Tighten the nut to 20 N.m (15 lb ft). 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12119 Hose/Line HVAC: Service and Repair Suction Screen Installation SUCTION SCREEN INSTALLATION TOOLS REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-6 Sizing Tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to the J 44551-5 Screen Installation Tool. 4. Install the J 44551-5 (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of the J 44551-5.The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT: Correct placement of the J 44551-5 is critical. 6. Remove the J 44551-5 from the suction hose. 7. Install the J 44551-1 Suction Screen Notification Label. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12120 Hose/Line HVAC: Service and Repair Evaporator Hose Assembly EVAPORATOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose from the evaporator hose. 3. Remove and discard the seal washer. 4. Remove the retainer clamp from the evaporator hose. 5. Remove the condenser tube and the evaporator hose from the thermal expansion valve (TXV). IMPORTANT: You may have to position the wires aside to remove the evaporator hose. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser Tube > Page 12121 6. Remove and discard the seal washers. INSTALLATION PROCEDURE 1. Install new sealing washers on the condenser tube and evaporator hose fittings. 2. Install the condenser tube and evaporator hose to the TXV. 3. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 20 N.m (15 lb ft). 4. Install the new seal washer to the compressor hose. 5. Install the compressor hose and nut to the evaporator hose. Tighten the nut to 20 N.m (15 lb ft). 6. Install the retainer clamp to the evaporator hose. 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor Housing Assembly HVAC: Customer Interest A/C - Water Leaks Onto The Passenger Floor Bulletin No.: 05-01-38-016B Date: August 16, 2006 TECHNICAL Subject: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover) Models: 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to provide the part number of the screw that is required for the Cobalt and Pursuit models. Please discard Corporate Bulletin Number 05-01-38-016A (Section 01 HVAC). Built Prior to the VIN breakpoints shown. Condition Some customers may comment on water leaking on the front passenger side floor of the vehicle. This leak would occur under high ambient temperatures and high humidity situations when the customer has the air conditioning on high. Leaks will appear to be coming from the HVAC module where the heater core cover and lower case come together. Also, some customers may comment on water droplets blowing out of the vents when the A/C is on high. Cause This condition may be due to water condensing in the HVAC case that adheres to the upper surface in the tongue and groove area of the lower case and then leaking out. Correction Install the foam gasket between the heater core cover and the lower HVAC case at the location of the leak using the procedure listed below. 1. Remove the right side insulator/closeout panel retainers and the panel, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12130 2. Remove the 5 screws (1) (HHR) or break the 4 welds (2) (Cobalt/Pursuit) from the heater core cover at the specified locations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12131 3. Carefully pry apart the heater core cover and the lower HVAC case to achieve a 12.7 mm (0.5 in) gap. 4. Install the foam gasket, P/N 15878211, using a flat rigid tool (feeler gauge shown) into the sump area (1) of the heater core cover. 5. Reassemble the case using the 5 screws that were removed (HHR) or with new screws (Cobalt/Pursuit), P/N 11609829. For Cobalt/Pursuit, add an additional screw (2) at rear of sump area. 6. Install the right side insulator/closeout panel and retainers, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12132 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Housing Assembly HVAC: Customer Interest A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 12137 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor Housing Assembly HVAC: All Technical Service Bulletins A/C - Water Leaks Onto The Passenger Floor Bulletin No.: 05-01-38-016B Date: August 16, 2006 TECHNICAL Subject: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover) Models: 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to provide the part number of the screw that is required for the Cobalt and Pursuit models. Please discard Corporate Bulletin Number 05-01-38-016A (Section 01 HVAC). Built Prior to the VIN breakpoints shown. Condition Some customers may comment on water leaking on the front passenger side floor of the vehicle. This leak would occur under high ambient temperatures and high humidity situations when the customer has the air conditioning on high. Leaks will appear to be coming from the HVAC module where the heater core cover and lower case come together. Also, some customers may comment on water droplets blowing out of the vents when the A/C is on high. Cause This condition may be due to water condensing in the HVAC case that adheres to the upper surface in the tongue and groove area of the lower case and then leaking out. Correction Install the foam gasket between the heater core cover and the lower HVAC case at the location of the leak using the procedure listed below. 1. Remove the right side insulator/closeout panel retainers and the panel, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12143 2. Remove the 5 screws (1) (HHR) or break the 4 welds (2) (Cobalt/Pursuit) from the heater core cover at the specified locations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12144 3. Carefully pry apart the heater core cover and the lower HVAC case to achieve a 12.7 mm (0.5 in) gap. 4. Install the foam gasket, P/N 15878211, using a flat rigid tool (feeler gauge shown) into the sump area (1) of the heater core cover. 5. Reassemble the case using the 5 screws that were removed (HHR) or with new screws (Cobalt/Pursuit), P/N 11609829. For Cobalt/Pursuit, add an additional screw (2) at rear of sump area. 6. Install the right side insulator/closeout panel and retainers, if equipped. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-01-38-016B > Aug > 06 > A/C - Water Leaks Onto The Passenger Floor > Page 12145 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Housing Assembly HVAC: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 12150 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement Housing Assembly HVAC: Service and Repair Evaporator and Blower Module Assembly Replacement AIR CONDITIONING (A/C) EVAPORATOR AND BLOWER MODULE ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module from the vehicle. 2. Remove the heat stakes from the heater core cover using a small chisel and remove the cover. 3. Remove the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12153 4. Remove the heat stakes that secure the lower HVAC case to the HVAC module using a small chisel. 5. Unsnap and open the passenger compartment filter door. 6. Remove the lower HVAC case. 7. Remove the evaporator core. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12154 1. Install the evaporator core into the HVAC module assembly. 2. Install the lower HVAC case. IMPORTANT: Verify that the orifice plate is correctly positioned in the HVAC module. Verify that the lower HVAC case is properly positioned and is fully seated on the HVAC module. Install new screws that will secure the lower HVAC case to the HVAC module. 3. Install the lower HVAC case screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.8 N.m (16 lb in). 4. Close and secure the passenger compartment filter door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12155 5. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. 6. Install the heater core into the HVAC module. 7. Install the heater core cover and the screws. IMPORTANT: Verify that the heater core cover is properly positioned and is fully seated on the HVAC module. Install new screws that secure the heater core cover to the HVAC module. Tighten the screws to 1.8 N.m (16 lb in). 8. Replace the drain tube seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12156 9. Replace the front of dash seal. 10. Inspect and replace the following HVAC module seals if damaged: - The defrost duct seal - The HVAC module to cross car duct seal - The center air outlet duct seal - The center floor air outlet duct seal - The air inlet seal 11. Install the HVAC module in the vehicle. 12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings using J 39400-A. 14. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12157 Housing Assembly HVAC: Service and Repair Heater Assembly Replacement HEATER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module from the vehicle. 2. Remove the heater core cover heat stakes. 3. Remove the heater core cover. 4. Remove the heater core. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12158 5. Remove the lower HVAC case heat stakes. 6. Unsnap and open the passenger compartment filter door. 7. Remove the lower HVAC case. INSTALLATION PROCEDURE 1. Install the lower HVAC case. IMPORTANT: Make certain that the orifice plate is correctly positioned in the HVAC module. Make certain that the lower HVAC case is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all lower HVAC case screws. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12159 2. Install the new lower HVAC case screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 1.8 N.m (15 lb in). 3. Close and secure the passenger compartment filter door. 4. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent. 5. Install the heater core into the HVAC module. 6. Install the heater core cover. IMPORTANT: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12160 Tighten the screws to 1.8 N.m (15 lb in). 7. Install new heater core cover screws 8. Replace the drain tube seal. 9. Replace the front of dash seal. 10. Inspect and replace the HVAC module seals if damaged: - The defrost duct seal - The HVAC module to cross car duct seal - The center air outlet duct seal - The center floor air outlet duct seal - The air inlet seal 11. Install the HVAC module in the vehicle. 12. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12161 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 39400-A Halogen Leak Detector - SA9111E Hose Clamp Pliers CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Drain the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. 4. Reposition the heater outlet hose clamp at the heater core using SA9111E. 5. Remove the heater outlet hose from the heater core. 6. Position the hose upright against the front of dash. 7. Reposition the heater inlet hose clamp at the heater core using SA9111E. 8. Remove the heater inlet hose from the heater core. 9. Position the hose upright against the front of dash. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12162 10. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 11. Remove and discard the seal washers. 12. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts. 13. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module. 14. Disconnect the blower motor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12163 15. Disconnect the blower motor resistor electrical connector. 16. Remove the instrument panel (I/P) retainer. 17. Disconnect the recirculation actuator electrical connector. 18. Remove the cross car beam retaining bolts. 19. Remove the cross car beam. 20. Remove the HVAC module from the vehicle. INSTALLATION PROCEDURE 1. Replace the drain tube seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12164 2. Replace the front of dash seal. 3. Inspect and replace the HVAC module seals if damaged: - The defrost duct seal - The HVAC module to cross car duct seal - The center air outlet duct seal - The center floor air outlet duct seal - The air inlet seal 4. Place the HVAC module in the vehicle. Align the HVAC module drain tube and front of dash studs to the vehicle. 5. Install the cross car beam. 6. Install the cross car beam retaining bolts. 7. Connect the recirculation actuator electrical connector. 8. Install the I/P retainer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12165 9. Connect the blower motor connector. 10. Connect the blower motor resistor electrical connector. 11. Align the center floor duct with the HVAC module. 12. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module. 13. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts. 14. Slide the center floor outlet duct down into position in the floor ducts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12166 15. Install the heater outlet hose to the heater core. 16. Reposition the hose clamp to secure the hose using SA9111E. 17. Install the heater inlet hose to the heater core. 18. Reposition the hose clamp to secure the hose using SA9111E. 19. Install new sealing washers on the condenser tube and evaporator hose fittings. 20. Install the condenser tube and evaporator hose to the TXV. 21. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 20 N.m (15 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator and Blower Module Assembly Replacement > Page 12167 22. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 23. Leak test the fittings using the J 39400-A. 24. Connect the negative battery cable. 25. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61)) in Cooling System. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy Refrigerant: Customer Interest A/C - Not Cold Enough/Compressor Noisy Bulletin No.: 05-01-38-005A Date: July 29, 2005 TECHNICAL Subject: A/C System Not Cold Enough, Noisy A/C Compressor (Recharge A/C System With Correct Amount of Refrigerant) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To December 6, 2004 Supercede: This bulletin is being revised to add a build date for when the condition was corrected on production vehicles. Please discard Corporate Bulletin Number 05-01-38-005 (Section 01 - HVAC). Condition Important: The refrigerant charge amount was corrected on vehicles built beginning on December 6, 2004. Vehicles built before this date may have an incorrect refrigerant charge amount. Some customers may comment on the Air Conditioning (A/C) system not blowing cold air. Others may comment that the windshield does not clear as quickly as expected while in the defrost mode. Technicians may hear a noise in the engine compartment coming from the A/C compressor. Cause If the Service Engine Soon (SES) light is not on, the root cause of the customer concern may be an overcharge of A/C system refrigerant. Correction Technicians are to recover, evacuate and then recharge the A/C system with the correct amount of refrigerant using the following procedure: 1. Open the hood and connect a J43600 ACR2000 Air Conditioning Service Center to the vehicle. 2. Start the vehicle and turn on the A/C system. 3. Verify that the A/C compressor is operating and that the Service Engine Soon light is not on. If the A/C system is not operating or the Service Engine Soon light is on, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 4. Turn off the ignition. 5. Recover, evacuate and then recharge the A/C system. 6. Start the vehicle and verify proper operation of the A/C system. 7. If the A/C system does not operate properly or is still noisy, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 8. Disconnect the ACR2000 and close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy > Page 12176 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-01-38-001 > Jan > 08 > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-01-39-007 > Jul > 06 > A/C - Contaminated R134A Refrigerant > Page 12186 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy Refrigerant: All Technical Service Bulletins A/C - Not Cold Enough/Compressor Noisy Bulletin No.: 05-01-38-005A Date: July 29, 2005 TECHNICAL Subject: A/C System Not Cold Enough, Noisy A/C Compressor (Recharge A/C System With Correct Amount of Refrigerant) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To December 6, 2004 Supercede: This bulletin is being revised to add a build date for when the condition was corrected on production vehicles. Please discard Corporate Bulletin Number 05-01-38-005 (Section 01 - HVAC). Condition Important: The refrigerant charge amount was corrected on vehicles built beginning on December 6, 2004. Vehicles built before this date may have an incorrect refrigerant charge amount. Some customers may comment on the Air Conditioning (A/C) system not blowing cold air. Others may comment that the windshield does not clear as quickly as expected while in the defrost mode. Technicians may hear a noise in the engine compartment coming from the A/C compressor. Cause If the Service Engine Soon (SES) light is not on, the root cause of the customer concern may be an overcharge of A/C system refrigerant. Correction Technicians are to recover, evacuate and then recharge the A/C system with the correct amount of refrigerant using the following procedure: 1. Open the hood and connect a J43600 ACR2000 Air Conditioning Service Center to the vehicle. 2. Start the vehicle and turn on the A/C system. 3. Verify that the A/C compressor is operating and that the Service Engine Soon light is not on. If the A/C system is not operating or the Service Engine Soon light is on, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 4. Turn off the ignition. 5. Recover, evacuate and then recharge the A/C system. 6. Start the vehicle and verify proper operation of the A/C system. 7. If the A/C system does not operate properly or is still noisy, refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure. 8. Disconnect the ACR2000 and close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-01-38-005A > Jul > 05 > A/C - Not Cold Enough/Compressor Noisy > Page 12191 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. Utility Storage Compartment Door / Cover: All Technical Service Bulletins Interior - Instrument Panel Compartment Bin Inop. TECHNICAL Bulletin No.: 09-08-49-018 Date: November 20, 2009 Subject: Instrument Panel (I/P) Outer Compartment Bin is Inoperative or Loose (Replace Steering Column Opening Filler Panel) Models: 2005-2010 Chevrolet Cobalt 2007-2009 Pontiac G5 2010 Pontiac G5 (Canada Only) Condition Some customers may comment that the instrument panel (I/P) outer compartment bin (1) is inoperative or loose. Cause This condition may be caused by the outboard pivot (1) on the steering column opening filler panel breaking and not properly holding the compartment bin in place. Correction Replace the steering column opening filler panel and transfer the compartment bin and necessary components to the new panel. Refer to Steering Column Opening Filler Replacement in SI. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. > Page 12197 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. > Page 12203 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 1.0 lbs (0.45 kg) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 12206 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 12207 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair Refrigerant Filter: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV). 3. Remove and discard the seal washer. 4. Remove the refrigerant filter from the condenser tube. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Page 12211 1. Install the refrigerant filter into the condenser tube. 2. Install new sealing washers on the condenser tube and evaporator hose fittings. 3. Install the condenser tube and evaporator hose to the TXV. 4. Install the TXV nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 20 N.m (15 lb ft). 5. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ABRUPT REFRIGERANT LOSS ........................................................................................................................................................... 60 ml (2.0 oz) NOTE: Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 74 ml (2.5 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. CONDENSER REPLACEMENT .......................................................................................................................................................... 22 ml (0.75 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. EVAPORATOR REPLACEMENT ....................................................................................................................................................... 22 ml (0.75 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 148 ml (5.0 oz) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 12218 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL Polyalkylene glycol (PAG) Oil ................................................................................................................ GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 12219 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Front Lower Left Of The Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12223 A/C Refrigerant Pressure Sensor (With RPO Code C67) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12224 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the pressure sensor. 3. Remove the pressure sensor from the compressor hose. 4. Remove and discard the seal. INSTALLATION PROCEDURE 1. Install a new seal in the pressure sensor. 2. Install the pressure sensor to the compressor hose. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the pressure sensor to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12225 3. Connect the pressure sensor electrical connector. 4. Lower the vehicle. 5. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Switch: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Blower Motor Switch: Customer Interest A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Switch: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 12235 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Switch: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob Blower Motor Switch: All Technical Service Bulletins A/C - Broken Blower Motor Control Knob Bulletin No.: 05-01-38-010A Date: June 27, 2006 TECHNICAL Subject: Broken Blower Motor Control Knob (Replace Knob) Models: 2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on a broken blower motor control knob. Correction Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Switch: > 05-01-38-010A > Jun > 06 > A/C - Broken Blower Motor Control Knob > Page 12241 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Front Lower Left Of The Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12245 A/C Refrigerant Pressure Sensor (With RPO Code C67) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12246 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the pressure sensor. 3. Remove the pressure sensor from the compressor hose. 4. Remove and discard the seal. INSTALLATION PROCEDURE 1. Install a new seal in the pressure sensor. 2. Install the pressure sensor to the compressor hose. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the pressure sensor to 5 N.m (44 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 12247 3. Connect the pressure sensor electrical connector. 4. Lower the vehicle. 5. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair Service Port HVAC: Service and Repair SERVICE PORT VALVE CORE REPLACEMENT TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 46246 Valve Core Tool REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the service port valve core using J 46246 or equivalent. INSTALLATION PROCEDURE 1. Install the service port valve core using J 46246 or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the service port valve core to 2.5 N.m (22 lb in). 2. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 3. Leak test the fittings using the J 39400-A. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT AIR BAG DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. - Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware, as needed. The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. - The seat belts-Perform the seat belt operational and functional checks. Refer to Repairs and Inspections Required After a Collision in Seat Belts. - The I/P cross car beam-Inspect for bending, twisting, buckling, or any other type of damage. - The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. - The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. - The roof and headliner mounting points ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving air bag deployment, replace the following components: The inflatable restraint I/P module - The inflatable restraint steering wheel module - The inflatable restraint sensing and diagnostic module (SDM) - The inflatable restraint front end sensor - The inflatable restraint seat belt retractor pretensioners Perform additional inspections on the following components: - Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, and pretensioners-Inspect for any damage and repair or replace each component, as needed. ACCIDENT WITH SIDE AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving side air bag deployment, replace the following components: The inflatable restraint side impact sensors (SIS), left/right, on the side of the impact - The inflatable restraint roof rail module, left/right, on the side of the impact - The inflatable restraint SDM - The inflatable restraint seat belt retractor pretensioner Perform additional inspections on the following components: Mounting points or mounting hardware for the SIS, and side impact module (LF/RF) on the side of impact-Inspect for any damage and repair or replace each component, as needed. - Mounting points or mounting hardware for the roof rail module (left/right) on the side of impact-Inspect for any damage and repair or replace each component, as needed. - Mounting points or mounting hardware for the SDM and seat belt pretensioners-Inspect for any damage and repair or replace each component, as needed. SENSOR REPLACEMENT GUIDELINES The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a diagnostic trouble Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12256 code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12257 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary unless some of the parts are torn, worn, or damaged. After any collision, verify that the pretentioners on the front seat belt retractor have not deployed. 1. Pull the seat belt webbing. 2. If you hear a grinding or a rattling, replace the retractor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12258 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection Inspection This vehicle is equipped with electric power steering (EPS), with the electric motor and torque sensor mounted on the steering column. When involved in an accident resulting in sheet metal damage or driver-side air bag deployment, the steering column must be inspected for both electrical system integrity and steering column collapse. Refer to Diagnostic System Check Vehicle. ^ If the steering column electrical system integrity is not within specifications, the complete steering column must be replaced. ^ If the steering column collapse mechanism is not within specifications, but the electrical system integrity is within specifications, then the steering column upper jacket must be replaced. Road test the vehicle when ever any steering system repairs or diagnostics have been performed. Electric Power Steering (EPS) Inspection Steps 1 - 2 2 Tests if the steering column is damaged due to a previous accident or airbag deployment. Collapse Measurement A vehicle involved in an accident resulting in sheet metal damage or drivers-side air bag deployment will require an inspection for steering column collapse. If the steering column collapse measurement is greater than 3 mm than the steering column upper jacket must be replaced. For steering column collapse measurement, use the following procedure: 1. Remove the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12259 2. Inspect the upper steering column mounting capsule nuts for movement (a). If the steering column collapse measurement is greater than 3 mm than the steering column upper jacket must be replaced. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12265 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12266 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12267 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12268 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12269 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12270 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12271 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12272 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12273 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12274 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12275 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12276 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12277 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12278 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12279 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12280 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12281 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12282 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12283 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12284 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12285 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12286 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12287 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12288 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12289 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12290 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12291 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect Technical Service Bulletin # 05034A Date: 050722 Campaign - Air Bag, A/C Wiring Defect A/C System Wiring or Dual Stage Airbag Module Wiring # 05034A - (Jul 22, 2005) Models: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05034 ISSUED MAY 2005. Condition Certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles have one of two conditions, 1) the steering column mounted airbag module wiring may be reversed. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owner's manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag would deploy fully instead of at the reduced level described in your owner's manual, or 2) vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). Correction Dealers are to 1) modify the circuitry to the airbag module, or 2) install wiring to isolate the voltage spike. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Important: Vehicles involved in this program require only one of the two repair procedures listed in this bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12301 Determine the appropriate procedure to perform on the vehicle. ^ If the vehicle is equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the A/C Wiring (Jumper) Procedure ^ If the vehicle is NOT equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the Airbag Wiring Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag A/C Wiring (Jumper) Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12302 Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12303 Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12304 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation Technical Service Bulletin # 05046A Date: 050722 Campaign - Air Bag, A/C Wiring Installation A/C System Wiring and Dual Stage Airbag Module Wiring # 05046A - (Jul 22, 2005) Model: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT EQUIPPED WITH A 2.2L ENGINE (L61) AND AIR CONDITIONING (C67) THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05046 ISSUED MAY 2005. Condition On certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). In addition, the steering column mounted airbag module wiring is reversed on these vehicles. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owners manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag will deploy fully instead of at the reduced level described in your owner's manual Correction Dealers are to install wiring to isolate the voltage spike and modify the circuitry to the airbag module. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Important: An initial supply of harnesses required to complete this recall will be preshipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 2, 2005, and will be approximately 10% of each dealer's involved vehicles. Preshipped parts will be charged to dealer's open parts account. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12309 Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag. 21. Proceed to the A/C Wiring (Jumper) Procedure below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12310 A/C Wiring (Jumper) Procedure Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12311 Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12318 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12319 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12325 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12326 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect Technical Service Bulletin # 05034A Date: 050722 Campaign - Air Bag, A/C Wiring Defect A/C System Wiring or Dual Stage Airbag Module Wiring # 05034A - (Jul 22, 2005) Models: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05034 ISSUED MAY 2005. Condition Certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles have one of two conditions, 1) the steering column mounted airbag module wiring may be reversed. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owner's manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag would deploy fully instead of at the reduced level described in your owner's manual, or 2) vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). Correction Dealers are to 1) modify the circuitry to the airbag module, or 2) install wiring to isolate the voltage spike. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Important: Vehicles involved in this program require only one of the two repair procedures listed in this bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12331 Determine the appropriate procedure to perform on the vehicle. ^ If the vehicle is equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the A/C Wiring (Jumper) Procedure ^ If the vehicle is NOT equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the Airbag Wiring Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag A/C Wiring (Jumper) Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12332 Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12333 Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12334 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation Technical Service Bulletin # 05046A Date: 050722 Campaign - Air Bag, A/C Wiring Installation A/C System Wiring and Dual Stage Airbag Module Wiring # 05046A - (Jul 22, 2005) Model: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT EQUIPPED WITH A 2.2L ENGINE (L61) AND AIR CONDITIONING (C67) THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05046 ISSUED MAY 2005. Condition On certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). In addition, the steering column mounted airbag module wiring is reversed on these vehicles. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owners manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag will deploy fully instead of at the reduced level described in your owner's manual Correction Dealers are to install wiring to isolate the voltage spike and modify the circuitry to the airbag module. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Important: An initial supply of harnesses required to complete this recall will be preshipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 2, 2005, and will be approximately 10% of each dealer's involved vehicles. Preshipped parts will be charged to dealer's open parts account. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12339 Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag. 21. Proceed to the A/C Wiring (Jumper) Procedure below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12340 A/C Wiring (Jumper) Procedure Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12341 Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12342 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12348 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12349 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect Technical Service Bulletin # 05034A Date: 050722 Campaign - Air Bag, A/C Wiring Defect A/C System Wiring or Dual Stage Airbag Module Wiring # 05034A - (Jul 22, 2005) Models: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05034 ISSUED MAY 2005. Condition Certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles have one of two conditions, 1) the steering column mounted airbag module wiring may be reversed. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owner's manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag would deploy fully instead of at the reduced level described in your owner's manual, or 2) vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). Correction Dealers are to 1) modify the circuitry to the airbag module, or 2) install wiring to isolate the voltage spike. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Important: Vehicles involved in this program require only one of the two repair procedures listed in this bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12355 Determine the appropriate procedure to perform on the vehicle. ^ If the vehicle is equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the A/C Wiring (Jumper) Procedure ^ If the vehicle is NOT equipped with a 2.2L engine (L61) AND air conditioning (C67), perform only the Airbag Wiring Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag A/C Wiring (Jumper) Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12356 Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12357 Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05034A > Jul > 05 > Campaign - Air Bag, A/C Wiring Defect > Page 12358 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation Technical Service Bulletin # 05046A Date: 050722 Campaign - Air Bag, A/C Wiring Installation A/C System Wiring and Dual Stage Airbag Module Wiring # 05046A - (Jul 22, 2005) Model: 2005 CHEVROLET COBALT 2005 PONTIAC PURSUIT EQUIPPED WITH A 2.2L ENGINE (L61) AND AIR CONDITIONING (C67) THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05046 ISSUED MAY 2005. Condition On certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70°F (21°C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h). In addition, the steering column mounted airbag module wiring is reversed on these vehicles. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owners manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag will deploy fully instead of at the reduced level described in your owner's manual Correction Dealers are to install wiring to isolate the voltage spike and modify the circuitry to the airbag module. Vehicles Involved Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Important: An initial supply of harnesses required to complete this recall will be preshipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 2, 2005, and will be approximately 10% of each dealer's involved vehicles. Preshipped parts will be charged to dealer's open parts account. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12363 Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Airbag Wiring Procedure 1. Remove the SIR fuse from the BCM. 2. With a flat-bladed tool, separate the outer trim cover from the I/P. 3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs. 4. Remove the outer trim cover from the I/P. 5. Disconnect the electrical connector from the trim cover. 6. Remove the connector position assurance (CPA) clip from the connector. 7. Disconnect the connector. 8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector. 9. Remove the terminal position assurance (TPA) clip from the male side of the connector. 10. Remove the TPA. 11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1). 12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2). 13. Install the TPA clip to the male terminal. 14. Rewrap the wiring. 15. Connect the connector and insert the CPA clip. 16. Connect the connector to the trim cover. 17. Align the outer trim cover locating tabs to the opening in the I/P. 18. Push the outer trim cover locating tabs into the I/P until fully engaged. 19. Press the outer trim cover into the I/P until fully secured. 20. Install the fuse for the airbag. 21. Proceed to the A/C Wiring (Jumper) Procedure below. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12364 A/C Wiring (Jumper) Procedure Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below. 1. Open the hood. 2. Remove the engine sight shield. Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer. 3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan. 4. Plug the new jumper into the fan and plug the original fan wiring into the jumper. 5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts. 6. Install the engine sight shield. 7. Close the hood. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Program Claim with the information shown. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12365 Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 05046A > Jul > 05 > Campaign - Air Bag, A/C Wiring Installation > Page 12366 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12375 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12376 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12382 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12383 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 12384 Air Bag Control Module: Locations Seat Belt Pretensioners - Coupe Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 12385 Seat Belt Pretensioners - Sedan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12388 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12389 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12390 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12391 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12392 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12393 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12394 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12395 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12396 Air Bag Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12397 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12398 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12399 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12400 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12401 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12402 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12403 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12404 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12405 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12406 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12407 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12408 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12409 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12410 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12411 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12412 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12413 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12414 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12415 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12416 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12417 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12418 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12419 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12420 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12421 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12422 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12423 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12424 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12425 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12426 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12427 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12428 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12429 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12430 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12431 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12432 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12433 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12434 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12435 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12436 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12437 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12438 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12439 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12440 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12441 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12442 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12443 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12444 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12445 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12446 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12447 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12448 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12449 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12450 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12451 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12452 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12453 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12454 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12455 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12456 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12457 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12458 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12459 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12460 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12461 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12462 Air Bag Control Module: Connector Views Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12463 Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12464 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12465 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 12466 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the supplemental inflatable restraint (SIR) system. This SDM has 2 fused power inputs; one fuse is for the battery voltage and the other fuse is for the ignition voltage. The SDM uses vehicle battery voltage as its main power input. The SDM then uses the vehicles GMLAN Serial Data Communication line and the ignition voltage logic input for enabling or disabling the SIR deployment loops. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags or seat belt pretensioners. If the force of the impact is not sufficient to warrant inflator module deployment, the SDM may still deploy the seat belt pretensioners. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. As soon as 3 distinct deployment commands (representing different events) have been issued to any belt pretensioner, or the SDM commands any front and side air bag to deploy once, the SDM shall be considered to not be reusable. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 12467 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 12468 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Inflatable Restraint Steering Wheel Module Coil C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 12472 Inflatable Restraint Steering Wheel Module Coil C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 12473 Inflatable Restraint Steering Wheel Module Coil C3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 12474 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of 2 or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the steering wheel module deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories that are attached to the steering wheel, depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the steering wheel module when the connector is disconnected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 12475 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Place the front wheels in the straight forward position with the steering wheel centered. NOTE: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3. 3. Remove the inflatable restraint steering wheel module. 4. Remove the steering wheel. 5. Remove the steering column covers. 6. Disconnect the SIR coil harness connector from the SIR coil module assembly. 7. Disconnect the headlamp/turn signal harness connector from the SIR coil module assembly. 8. Disconnect the wiper/washer harness connector for the SIR coil module assembly. 9. Using a small flat-bladed tool, carefully pry the 2 retaining tabs away at the base of the SIR coil assembly and slide the SIR coil assembly off of the steering column. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 12476 10. Remove the headlamp/turn signal switch from the SIR coil module assembly. 11. Remove the wiper washer switch from the SIR coil module assembly. INSTALLATION PROCEDURE 1. Install the wiper washer switch from the SIR coil module assembly. 2. Install the headlamp/turn signal switch to the SIR coil module assembly. 3. Install the headlamp/turn signal switch screws. 4. Verify the SIR coil is in the center position. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. 5. Slide the SIR coil assembly on the steering column and snap into place. 6. Connect the wiper/washer harness connector to the SIR coil module assembly. 7. Connect the headlamp/turn signal harness connector to the SIR coil module assembly. 8. Connect the SIR coil harness connector to the SIR coil module assembly. 9. Install the steering column covers. 10. Install the steering wheel. 11. Install the inflatable restraint steering wheel module. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Front End Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions Impact Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12482 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12483 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12484 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12485 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12486 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12487 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12488 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12489 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12490 Impact Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12491 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12492 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12493 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12494 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12495 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12496 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12497 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12498 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12499 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12500 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12501 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12502 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12503 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12504 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12505 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12506 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12507 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12508 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12509 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12510 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12511 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12512 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12513 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12514 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12515 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12516 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12517 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12518 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12519 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12520 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12521 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12522 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12523 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12524 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12525 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12526 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12527 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12528 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12529 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12530 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12531 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12532 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12533 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12534 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12535 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12536 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12537 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12538 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12539 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12540 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12541 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12542 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12543 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12544 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12545 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12546 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12547 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12548 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12549 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12550 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12551 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12552 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12553 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12554 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12555 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12556 Impact Sensor: Connector Views Inflatable Restraint Side Impact Sensor - Left (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12557 Inflatable Restraint Side Impact Sensor - Right (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12558 Inflatable Restraint Front End Discriminating Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor Impact Sensor: Description and Operation Front End Sensor INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on vehicles to supplement the supplemental inflatable restraint (SIR) system performance. The front end sensor is an electronic sensor and is not part of the deployment loops, but instead provides an input to the sensing and diagnostic module (SDM). The front end sensor can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor > Page 12561 Impact Sensor: Description and Operation Side Impact Sensor (SIS) INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12564 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12565 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12566 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System (PPS) Operation Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information > Page 12575 Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations Side Air Bag: Locations Driver Door Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 12579 Passenger Door Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 12580 Air Bags Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 12581 Side Air Bag: Diagrams Inflatable Restraint Roof Rail Module - Left (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 12582 Inflatable Restraint Roof Rail Module - Right (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Inflatable Restraint Roof Rail Modules Side Air Bag: Description and Operation Inflatable Restraint Roof Rail Modules INFLATABLE RESTRAINT ROOF RAIL MODULES The roof rail modules are located under the headliner extending from the front windshield pillar to the rear window pillar. The roof rail modules contain a housing, inflatable air bag, initiating device, and a canister of gas generating material. The initiator is part of the roof rail module deployment loop. When a side impact of sufficient force occurs the side impact sensor (SIS) detects the impact and sends a signal to the sensing and diagnostic module (SDM). The SDM compares the signal received from the SIS to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the side deployment loop deploying the roof rail air bags. The SDM, roof rail modules and the connecting wires makeup the side deployment loops. The SDM continuously monitors the deployment loops for malfunctions and turns the AIR BAG indicator ON if a fault is present. Each roof rail module is equipped with a shorting bar located on the connector of the module. The shorting bar shorts the roof rail modules deployment loop circuitry to prevent unwanted deployment of the air bag when servicing the inflator module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Inflatable Restraint Roof Rail Modules > Page 12585 Side Air Bag: Description and Operation Side SIR System SIDE SIR SYSTEM DESCRIPTION The side SIR system consists of the following components: - AIR BAG indicator located in the instrument panel cluster (IPC) - Inflatable restraint SDM - Inflatable restraint seat belt retractor pretensioners (left/right) - Inflatable restraint side impact sensors (SIS) (left/right) - Inflatable restraint roof rail modules (left/right) - Inflatable restraint wiring harnesses Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 12586 Side Air Bag: Service and Repair INFLATABLE RESTRAINT ROOF RAIL MODULE REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 12587 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the instrument panel cluster (IPC), is used to notify the driver of supplemental inflatable restraint (SIR) system malfunctions and to verify that the sensing and diagnostic module (SDM) is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition positive voltage. The SDM requests the IPC to flash the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts tests on all SIR system components and circuits. If no malfunctions are detected, the SDM will communicate with the IPC through the GMLAN serial data circuit and command the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a diagnostic trouble code (DTC) and command the IPC to turn the AIR BAG indicator ON via GMLAN serial data. The presence of a SIR system malfunction could result in non-deployment of the air bags or deployment in conditions less severe than intended. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation KNEE BOLSTER The knee bolsters are designed to help restrain the lower torso of front seat occupants by absorbing the energy through the front seat occupants upper legs. In a collision, the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush and deform, absorbing some of the impact and helping to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damages after a collision. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12607 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12608 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12614 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 12615 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 12616 Air Bag Control Module: Locations Seat Belt Pretensioners - Coupe Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 12617 Seat Belt Pretensioners - Sedan Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12620 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12621 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12622 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12623 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12624 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12625 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12626 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12627 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12628 Air Bag Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12629 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12630 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12631 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12632 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12633 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12634 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12635 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12636 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12637 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12638 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12639 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12640 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12641 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12642 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12643 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12644 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12645 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12646 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12647 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12648 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12649 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12650 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12651 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12652 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12653 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12654 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12655 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12656 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12657 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12658 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12659 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12660 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12661 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12662 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12663 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12664 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12665 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12666 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12667 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12668 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12669 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12670 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12671 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12672 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12673 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12674 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12675 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12676 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12677 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12678 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12679 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12680 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12681 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12682 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12683 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12684 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12685 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12686 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12687 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12688 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12689 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12690 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12691 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12692 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12693 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12694 Air Bag Control Module: Connector Views Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12695 Inflatable Restraint Sensing And Diagnostic Module (SDM) (With RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12696 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12697 Inflatable Restraint Sensing And Diagnostic Module (SDM) (Without RPO Code ASF) Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 12698 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the supplemental inflatable restraint (SIR) system. This SDM has 2 fused power inputs; one fuse is for the battery voltage and the other fuse is for the ignition voltage. The SDM uses vehicle battery voltage as its main power input. The SDM then uses the vehicles GMLAN Serial Data Communication line and the ignition voltage logic input for enabling or disabling the SIR deployment loops. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags or seat belt pretensioners. If the force of the impact is not sufficient to warrant inflator module deployment, the SDM may still deploy the seat belt pretensioners. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. As soon as 3 distinct deployment commands (representing different events) have been issued to any belt pretensioner, or the SDM commands any front and side air bag to deploy once, the SDM shall be considered to not be reusable. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 12699 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 12700 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System (PPS) Operation Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12710 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12711 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12712 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12713 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12714 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12715 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12716 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12717 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12718 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12719 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12720 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12721 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12722 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12723 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12724 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12725 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12726 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12727 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12728 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12729 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12730 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12731 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12732 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12733 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12734 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12735 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 12736 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Bezel Replacement - Child Restraint Tether Anchor Child Seat Tether Attachment: Service and Repair Bezel Replacement - Child Restraint Tether Anchor BEZEL REPLACEMENT - CHILD RESTRAINT TETHER ANCHOR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Bezel Replacement - Child Restraint Tether Anchor > Page 12742 Child Seat Tether Attachment: Service and Repair Child Restraint Tether Anchor Replacement CHILD RESTRAINT TETHER ANCHOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12747 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12748 Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Availability Bulletin No.: 06-09-40-001 Date: February 08, 2006 INFORMATION Subject: Seat Belt Stop Buttons Released For Service Use Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) The purpose of this bulletin is to announce the availability of the web stop button as a separate serviceable part. In the past, if the stop button came loose from the seat belt webbing, it was necessary to replace the entire seat belt assembly. The stop button is now available in three colors as listed below. Use the seat belt stop button labor operation listed below instead of the seat belt assembly replacement labor operation when replacing only the stop button. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12749 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 12750 Seat Belt: Service and Repair SEAT BELT REPLACEMENT - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 12751 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 12760 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 12766 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle: Service and Repair Rear SEAT BELT BUCKLE REPLACEMENT - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 12778 Seat Belt Buckle: Service and Repair Front SEAT BELT BUCKLE REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 12782 Seat Belt Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair Seat Belt Guide Track: Service and Repair GUIDE REPLACEMENT - REAR SEAT SHOULDER BELT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair SEAT BELT HEIGHT ADJUSTER REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12797 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12798 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12799 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Stop Button Availability Bulletin No.: 06-09-40-001 Date: February 08, 2006 INFORMATION Subject: Seat Belt Stop Buttons Released For Service Use Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) The purpose of this bulletin is to announce the availability of the web stop button as a separate serviceable part. In the past, if the stop button came loose from the seat belt webbing, it was necessary to replace the entire seat belt assembly. The stop button is now available in three colors as listed below. Use the seat belt stop button labor operation listed below instead of the seat belt assembly replacement labor operation when replacing only the stop button. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 12800 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 12801 Seat Belt Retractor: Testing and Inspection EMERGENCY LOCKING RETRACTORS CAUTION: Perform this test in an area clear of other vehicles or obstructions. Do not conduct this test on the open road. A large, empty parking lot is suitable. Failure to observe this precaution may result in damage to the vehicle and possible personal injury. 1. Fasten the seat belts. An assistant is needed when the retractor under test is not part of the driver seat belt. 2. Accelerate the vehicle slowly to 16 km/h (10 mph) and apply the brakes firmly. 3. Verify that the seat belt locks when braking firmly. 4. If the belt does not lock, proceed with the following steps. 1. Remove the seat belt retractor assembly. 2. Tilt the seat belt retractor slowly. 3. Ensure that the seat belt webbing can be pulled from the retractor at an inclination of 15 degrees or less and cannot be pulled from the retractor at an inclination of 45 degrees or more. 4. If the seat belt retractor does not operate as described, replace the retractor assembly. Refer to the following procedures: - Seat Belt Replacement - Front - Seat Belt Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 12802 Seat Belt Retractor: Service and Repair SEAT BELT RETRACTOR REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 12803 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Seat Belt Retractor Pretensioner - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 12807 Seat Belt Retractor Pretensioner - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 12808 Seat Belt Tensioner: Description and Operation INFLATABLE RESTRAINT SEAT BELT RETRACTOR PRETENSIONER The seat belt pretensioner modules contain a housing, a seat belt retractor, the seat belt webbing, an initiating device, and a canister of gas generating material. The initiator is part of the seat belt pretensioner deployment loop. When the vehicle is involved in a collision of sufficient force, the sensing and diagnostic module (SDM) will cause current to flow through the deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas and the release of compressed gas, if present. The gas produced from this reaction deploys the seat belt pretensioner and retracts the seat belt webbing, which removes slack in the seat belt. Depending on the severity of the collision, the seat belt pretension may deploy without the frontal inflator modules deploying, or they will deploy immediately before the frontal inflator modules deploy. As soon as 3 distinct deployment commands, representing different events, have been issued to any belt pretensioner, the SDM shall be considered to not be reusable. Each seat belt pretensioner is equipped with a shorting bar located on the connector of the pretensioner. The shorting bar shorts the seat belt pretensioner deployment loop circuitry to prevent unwanted deployment of the pretensioner when servicing the seat belt pretensioner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures Seat Belt Tensioner: Service and Repair Deployment Procedures DEPLOYMENT PROCEDURES The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12811 Seat Belt Tensioner: Service and Repair Pretensioner Handling and Scrapping PRETENSIONER HANDLING AND SCRAPPING CAUTION: When carrying an undeployed inflatable restraint seat belt retractor pretensioner: - Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped. - Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat belt webbing. - Make sure the opening, from which the seat belt webbing extends, faces downward and the seat belt webbing hangs freely. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor pretensioner in the following situations: After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor pretensioner may need to be returned undeployed to the manufacturer. - If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. - If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12812 Seat Belt Tensioner: Service and Repair Deployment Inside the Vehicle DEPLOYMENT INSIDE THE VEHICLE Refer to Inflator Module Handling and Scrapping for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12813 Seat Belt Tensioner: Service and Repair Deployment Outside Vehicle For Seat Belt Pretensioners DEPLOYMENT OUTSIDE VEHICLE FOR SEAT BELT PRETENSIONERS Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: - Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. - The seat belt pretensioner pigtail, if equipped, is damaged. - The seat belt retractor pretensioner connector is damaged. - The seat belt retractor pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. CAUTION: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Tools Required J 38826 SIR Deployment Harness - J 38826-25 for seat belt pretensioner module adapter - J 39401-B SIR Deployment Fixture - An appropriate pigtail adaptor 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt retractor pretensioner from the vehicle. 5. When carrying a seat belt retractor pretensioner to the deployment area, keep fingers clear of the seat belt webbing. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12814 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. 10. Mount the seat belt pretensioner in the SIR deployment fixture with the seat belt webbing exiting through the top of the pretensioner. Use the following mounting method. Adjust and secure two of the J 39401-B arms to the deployment fixture, with the short slotted portions of the arms standing vertically and facing toward the center of the deployment fixture. - To mount, use the proper size bolt and nut with washers in order to secure the seat belt pretensioner mounting hole between the two deployment fixture brackets. - Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12815 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector to the adapter on the deployment harness. 16. Clear the area of people. IMPORTANT: When deploying a seat belt retractor pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 17. Separate the 2 banana plugs on the SIR deployment harness. 18. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted end of the harness. IMPORTANT: When the seat belt retractor pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt retractor pretensioner deploys. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Deployment Procedures > Page 12816 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat belt retractor pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt retractor pretensioner as soon as possible. 25. Dispose of the deployed seat belt retractor pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Front End Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions Impact Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12823 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12824 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12825 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12826 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12827 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12828 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12829 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12830 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12831 Impact Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12832 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12833 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12834 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12835 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12836 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12837 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12838 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12839 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12840 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12841 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12842 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12843 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12844 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12845 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12846 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12847 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12848 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12849 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12850 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12851 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12852 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12853 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12854 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12855 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12856 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12857 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12858 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12859 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12860 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12861 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12862 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12863 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12864 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12865 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12866 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12867 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12868 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12869 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12870 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12871 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12872 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12873 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12874 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12875 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12876 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12877 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12878 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12879 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12880 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12881 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12882 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12883 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12884 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12885 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12886 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12887 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12888 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12889 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12890 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12891 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12892 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12893 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12894 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12895 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12896 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12897 Impact Sensor: Connector Views Inflatable Restraint Side Impact Sensor - Left (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12898 Inflatable Restraint Side Impact Sensor - Right (With RPO Code ASF) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 12899 Inflatable Restraint Front End Discriminating Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor Impact Sensor: Description and Operation Front End Sensor INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on vehicles to supplement the supplemental inflatable restraint (SIR) system performance. The front end sensor is an electronic sensor and is not part of the deployment loops, but instead provides an input to the sensing and diagnostic module (SDM). The front end sensor can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensor > Page 12902 Impact Sensor: Description and Operation Side Impact Sensor (SIS) INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12905 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12906 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12907 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 12911 Seat Belt Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information > Page 12916 Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System (PPS) Operation Bulletin No.: 07-09-41-003 Date: June 05, 2007 INFORMATION Subject: Passenger Presence System (PPS) Operation - Passenger Airbag Status Indicator Reads On When Installing Child Restraint in Front Passenger Seat Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 If a customer contacts your dealership and comments that the passenger air bag on indicator is lit when a child restraint has been installed in the front passenger seat, remind the customer: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. Even in vehicles equipped with the Passenger Presence System (PPS), children are safer when properly secured in a rear seat. Always use correct child restraint for your child's age and size. Never place a rear-facing infant restraint in the front. If the customer needs to install a forward facing child restraint in the front seat, instruct the customer to read and follow the instructions that came with the child restraint and the vehicle's Owner Manual instructions for securing a child restraint in the right front passenger seat, including the vehicle's Owner Manual instructions for what to do if the passenger air bag on indicator is lit after the child restraint has been installed. If a child restraint has been installed in the front passenger seat and the air bag on indicator is lit, turn the vehicle off. Remove the child restraint from the vehicle and reinstall the child restraint. If, after reinstalling the child restraint and restarting the vehicle, the air bag on indicator is still lit, check to make sure that the vehicle's seatback is not pressing the child restraint into the seat cushion. If this happens, slightly recline the vehicle's seatback and adjust the seat cushion if possible. Also make sure the child restraint is not trapped under the vehicle head restraint. If this happens, adjust the head restraint. If the on indicator is still lit, secure the child in the child restraint in a rear seat position in the vehicle and check with your dealer. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12922 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12923 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12924 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12925 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12926 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12927 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12928 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12929 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12930 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12931 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12932 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12933 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12934 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12935 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12936 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12937 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12938 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12939 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12940 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12941 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12942 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12943 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12944 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12945 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12946 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12947 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12948 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12949 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12950 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12951 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12952 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12953 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12954 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12955 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12956 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12957 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12958 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12959 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12960 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12961 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12962 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12963 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12964 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12965 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12966 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12967 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12968 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12969 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12970 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12971 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12972 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12973 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12974 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12975 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12976 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12977 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12978 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12979 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12980 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12981 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12982 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12983 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12984 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12985 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12986 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12987 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12988 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12989 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12990 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12991 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12992 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12993 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12994 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12995 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna > Page 13001 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 13015 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 13025 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 13030 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 13035 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > Page 13036 Global Positioning System Antenna: Service and Repair ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair COAXIAL CABLE REPLACEMENT - DIGITAL RADIO Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Locks - Remote Control Door Lock Receiver Replacement Keyless Entry Receiver: Technical Service Bulletins Locks - Remote Control Door Lock Receiver Replacement Bulletin No.: 05-08-52-003 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Remote Control Door Lock Receiver Replacement Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Remote Control Door Lock Receiver Replacement procedure in the Doors sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Locks - Remote Control Door Lock Receiver Replacement > Page 13047 The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 13048 Remote Control Door Lock Receiver (RCDLR) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 13049 Keyless Entry Receiver: Service and Repair The content of this article/image reflects the changes identified in TSB- 05-08-52-003 Dated: October 21, 2005 Remote Control Door Lock Reciever Replavement Components Procedure REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 13050 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics Keyless Starting System: Technical Service Bulletins Remote Starting System - System Inoperative Diagnostics INFORMATION Bulletin No.: 08-08-52-002 Date: February 27, 2008 Subject: Diagnostic Information for Inoperative Remote Vehicle Start Models: 2005-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2008 HUMMER H2 with Remote Keyless Entry RPOs AP3 or AP8 Remote Vehicle Start (RVS) Inoperative Diagnostic Concerns Information on Hood Latch Switches One of the many components involved in the Remote Vehicle Starting System is the Hood Latch Switch. The state of this switch is checked by the BCM during a remote vehicle start request and the component must function properly in order for the vehicle to commence a remote start event. During the infancy of this option (RPO AP3/AP8) parts return analysis showed a significantly shorter than expected component life for the Hood Latch Switch shared across many different GM vehicles. The switches currently being factory installed, and sent as service replacement parts, are vastly improved in design and suitably robust. Most hood latch switches currently returned under warranty are analyzed and determined to have no trouble found (NTF). It is understandable and desirable that technicians gain familiarity with the vehicles they service on a daily basis, however it is required that technicians follow Strategy Based Diagnostics before replacing this switch. Important: The ONLY way to repair or replace a hood latch switch is to replace the LATCH ASSEMBLY. The switch CANNOT be serviced separately from the latch and is NOT AVAILABLE from GMSPO. Any effort to remove the switch from the latch will permanently damage the switch and void the warranty coverage of that part. Important: The hood switch provides status of the hood to the BCM for RVS purposes. The switch is integrated into the hood latch assembly. The hood ajar switch provides two separate inputs to the BCM. These separate inputs allow the BCM to actively monitor for a hood ajar switch fault. RVS System Operation The remote vehicle start (RVS) function allows engine starting while not in the vehicle. It also allows the vehicle HVAC system and other vehicle systems to enable providing a comfortable vehicle upon entry. RVS functions have an operating range of up to 59 m (195 ft) depending on conditions. The RVS sequence begins by pressing and releasing the lock button and then pressing and holding the RVS buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate the vehicle has received the remote start request. Each time an RVS is performed the vehicle doors are locked; however they may then be unlocked/locked with the transmitter or vehicle key at any time. Once activated the engine is allowed to run for 10 minutes. The RVS time may be extended by an additional 10 minutes by again pressing and releasing the lock button and then pressing and holding the RVS buttons on the transmitter. This feature is called an RVS continue and allows a maximum of 20 minutes of engine running. If the RVS continue is performed at 7 minutes into the initial 10 minute time-out a total of 17 minutes of engine running would occur. The RVS event may be suspended at any time by pressing only the RVS button on the transmitter or by entering the vehicle and turning ON the hazard lamps. RVS System Description Remote vehicle start (RVS) begins as a Radio Frequency (RF) message received by the remote control door lock receiver (RCDLR) from a keyless entry transmitter. The RVS request is sent by the RCDLR to the body control module (BCM) via serial data line. The BCM monitors system conditions such as content theft deterrent (CTD) closures ajar status and body DTCs to determine if an RVS event will occur. If conditions are determined to be acceptable the RVS message is sent to the engine control module (ECM). The ECM monitors system conditions such as engine control parameters and vehicle theft deterrent (VTD) to determine if engine starting will be allowed. If conditions are acceptable the ECM will initiate engine starting. During Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics > Page 13055 the engine run time in an RVS attempt before the operator enters the vehicle the ECM may discontinue engine operation if system conditions require it or a message is received from the BCM requesting the engine be turned OFF. Reasons an RVS event will NOT Happen The RVS System WILL NOT operate if any of the following conditions are present: ^ A current vehicle DTC that illuminates the malfunction indicator lamp (MIL) is set - obtain vehicle DTCs. ^ Keyless Entry Transmitter is not Operational. ^ The vehicle is in Valet Mode. ^ RVS is Disabled through Vehicle Personalization. ^ More than 2 Remote Starts have been attempted. ^ The HAZARD switch is in the ON position. ^ A current HAZARD switch DTC is set. ^ A current HOOD AJAR DTC is set. ^ Rear compartment lid is ajar. ^ Any Door is not locked. ^ The Content Theft Deterrent (CTD) system detects an alarm trigger. ^ Engine RPM greater than 0 Detected. ^ Excessive Coolant TEMP is registered. ^ Accelerator pedal position greater than 0 percent. ^ Vehicle is not in PARK. ^ A current Vehicle Theft Deterrent Malfunction DTC. ^ A current Automatic Transmission Shift Lock Control System DTC is set. ^ A vehicle speed sensor signal is detected by the ECM. ^ Vehicle power mode is incorrect. Diagnostic Information Starting Point For additional assistance refer to Remote Vehicle Start Inoperative in the Electronic Service Information. This section will guide you through the complete Strategy Based Diagnostics and provide Specific Diagnostic Procedure Instructions. Warranty Information Please refer to the published Labor Time Guides and claim the corresponding labor operation for the component(s) replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a flat object, with a thin edge, into the notch located below the remote alarm button and separate the bottom half from the top half of the transmitter. NOTE: When replacing the battery, use care not to touch any of the circuitry. Static from your body transferred to these surfaces may damage the transmitter. 2. Remove the battery from the transmitter. INSTALLATION PROCEDURE 1. Install the battery into the transmitter with the positive side of the battery facing up. 2. Snap the front and back half of the transmitter together. 3. Ensure the transmitter halves are tight to prevent moisture from intruding into the transmitter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams Cellular Microphone Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 13064 Cellular Phone Microphone: Service and Repair ONSTAR MICROPHONE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 13068 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 13069 Driver Information Center (DIC) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 13070 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) displays important vehicle information when it first powers up. The DIC is also used to display Odometer and Outside Air Temperature when other important vehicle information is not being displayed. The DIC switches are hardwired to and read by the IPC. The BCM is responsible for driving and processing the DIC display through GMLAN serial data. The BCM is responsible for reading the outside air temperature (OAT) and season odometer. The outside air temperature and season odometer is transmitted to the IPC over GMLAN for display in the DIC. The OAT data is transmitted in degrees Celsius and the cluster is responsible for converting the outside air temperature (OAT) to Fahrenheit. There are 2 DIC buttons on the instrument panel cluster (IPC): - INFO - RESET/SELECT The 2 DIC buttons however provide 3 switch functions. Pressing the INFO and RESET/SELECT button at the same time provides the MENU switch function. INFO The INFO button is used in order to navigate through the following driver information center (DIC) information modes: AV VEHICLE SPEED - AV FUEL ECON - COOLANT TEMPERATURE - FUEL RANGE - OIL LIFE MONITOR - TRIP ODOMETER A - TRIP ODOMETER B Other instrument panel cluster (IPC) information displayed in the DIC are Season odometer and Outside Air Temp. AV VEHICLE SPEED Average speed is calculated using the equation: Average Speed = Distance/Ignition On. Distance = The accumulated distance travelled since the last reset of this value. - Ignition On = The accumulated ignition on time since the last reset of this value. Ignition on time is measured from the time that the ignition is turned ON to the time when the ignition is turned OFF. The value of this mode is retained during ignition OFF. Press and hold the RESET/SELECT button on the DIC for 1 second in order to reset the average speed display. AV FUEL ECON Average fuel economy is calculated using the equation: AFE = Distance/Fuel. Distance = The accumulated distance travelled since the last reset of this value. - Fuel = The accumulated fuel consumption since the last reset of this value. The DIC receives a serial data message from the body control module (BCM) regarding fuel usage information. The value of this mode is retained during ignition OFF and can be changed between English units and metric units. Press and hold the RESET/SELECT button on the DIC switch for 1 second in order to reset the ECON display. COOLANT TEMPERATURE The DIC receives GMLAN serial data message from the BCM requesting the display of the coolant temperature. The coolant temperature is sent to the BCM as determined by the powertrain control module (PCM)/engine control module (ECM) via GMLAN serial data message. FUEL RANGE This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last reset of the value. Fuel Range is calculated using the equation: Fuel Range = Distance Sum/Fuel Sum. Distance Sum = The accumulated distance travelled since the last reset of this value. - Fuel Sum = The accumulated fuel delivered since the last reset of this value. The DIC receives a GMLAN serial data message from the BCM with fuel information. The value of this mode is retained during ignition OFF and can be changed between English units and metric units. The FUEL RANGE display cannot be reset. OIL LIFE MONITOR The PCM/ECM sends the oil life remaining percentage to the body control module (BCM) via a GMLAN serial data message. The DIC receives a serial data message from the BCM indicating the remaining oil life. The DIC displays the current percentage of the GM Oil Life System as determined by the PCM/ECM. TRIP ODOMETER A and TRIP ODOMETER B Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 13071 The DIC displays vehicle trip odometer mileage based on the vehicle speed signal (VSS) from the body control module (BCM). The trip odometer displays accumulated km (mi) since the last reset of this value. The trip odometer is capable of displaying up to 999.9 km (999.9 mi). Trip odometer information is not retained when the battery is disconnected. Press and hold the INFO button on the DIC for 1 second in order to reset the trip odometer display. RESET/SELECT The RESET/SELECT button is used in order to acknowledge a warning message, reset an option, or to select an option. Press and hold for 0.25 seconds to perform RESET/SELECT. MENU The MENU button is used in order to navigate through the following personalization modes: AUTO UNLK - DELAY LOCK - EXT LIGHTS - LANGUAGE - LIGHT FLASH - LOCK HORN - OIL-LIFE RESET - REMOTE START - SECURITY - UNITS - UNLOCK HORN OIL-LIFE RESET The powertrain control module (PCM)/engine control module (ECM) sends the oil life remaining percentage to the body control module (BCM) via a GMLAN serial data message. The driver information center (DIC) receives a GMLAN serial data message from the BCM indicating the remaining oil life. The DIC displays the current percentage of the GM Oil Life System as determined by the PCM/ECM. When the oil life remaining percentage drops below 10 percent, the DIC displays CHANGE ENGINE OIL. When the engine oil is changed, reset the engine oil life in order to clear the oil life remaining percentage display. Press and hold the RESET/SELECT button for 5 seconds until the DIC acknowledges. For more information on the rest of the personalization modes, refer to Personalization Description and Operation. Outside Air Temperature The outside air temperature is read by the body control module (BCM) and transmitted over serial data to the instrument panel cluster (IPC) for display in the driver information center (DIC). The BCM provides the logic for reading the outside air temperature sensor. The BCM sends the temperature to the IPC in Celsius. The IPC is responsible for displaying the temperature and converting to Fahrenheit. Odometer The odometer information is stored in the body control module (BCM) and is transmitted to the instrument panel cluster (IPC) for display in the driver information center (DIC). The IPC stores a backup copy of the odometer value in case the IPC does not receive a valid odometer reading form the BCM. The last known good odometer value from the BCM is displayed by the IPC before ERROR is displayed in the DIC. Indicators And Warning Messages For more information on driver information center (DIC) warning messages, refer to Indicator/Warning Message Description and Operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures DRIVER INFORMATION CENTER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 13074 Driver/Vehicle Information Display: Removal and Replacement Driver Information Center Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13083 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13084 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13085 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13086 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13087 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13088 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13089 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13090 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13091 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13092 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13093 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13094 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13095 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13096 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13097 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13098 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13099 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13100 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13101 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13102 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13103 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13104 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13105 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13106 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13107 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13108 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13109 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13110 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13111 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13112 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13113 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13114 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13115 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13116 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13122 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13127 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13132 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13133 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13139 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13148 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13149 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13150 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13151 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13152 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13153 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13154 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13155 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13156 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13157 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13158 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13159 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13160 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13161 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13162 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13163 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13164 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13165 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13166 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13167 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13168 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13169 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13170 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13171 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13172 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13173 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13178 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13179 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13180 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13181 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13182 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13183 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13184 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13185 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13186 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13187 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13188 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13189 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13190 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13191 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13192 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13193 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13194 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13195 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13196 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13197 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13198 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13199 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13200 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13201 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13202 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13203 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13204 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13205 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13206 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13207 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13208 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13209 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13210 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13211 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13216 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13217 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13218 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13219 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13220 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13221 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13222 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13223 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13224 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13225 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13226 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13227 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13232 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13245 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13250 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13251 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13257 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13266 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13267 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13268 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13269 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13270 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13271 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13272 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13273 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13274 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13275 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13276 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13277 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13278 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13279 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13280 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13281 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13282 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13283 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13284 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13285 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13286 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13287 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13288 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13289 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13290 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13291 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13296 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13297 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13298 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13299 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13300 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13301 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13302 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13303 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13304 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13305 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13306 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13307 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13312 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13325 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13330 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13331 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13341 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13342 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13343 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13344 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13345 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13346 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13347 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13348 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13349 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13350 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13351 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13352 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13353 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13354 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13355 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13356 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13357 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13358 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13359 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13360 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13361 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13362 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13363 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13364 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13365 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13366 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13371 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13372 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13373 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13374 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13375 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13376 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13377 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13378 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13379 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13380 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13381 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13382 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13383 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13384 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13385 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13386 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13387 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13388 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13389 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13390 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13391 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13392 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13393 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13394 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13395 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13396 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13397 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13398 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13399 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13400 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13401 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13402 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13403 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13404 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13409 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13410 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13411 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13412 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13413 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13414 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13415 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13416 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13417 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13418 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13419 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13420 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13425 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 13444 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > Page 13445 Global Positioning System Antenna: Service and Repair ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Locations Rear Compartments And Shelf Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Locations > Page 13449 Global Positioning System Module: Diagrams Vehicle Communication Interface Module (VCIM) C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Locations > Page 13450 Vehicle Communication Interface Module (VCIM) C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Locations > Page 13451 Vehicle Communication Interface Module (VCIM) C3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Locations > Page 13452 Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation Memory Positioning Systems: Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION PERSONALIZATION The following options can be accessed in order by pressing the MENU button anytime while the vehicle is in ON. Pressing the INFO and RESET/SELECT buttons at the same time provides the MENU switch function. Press the MENU button to scroll through each option. All of the personalization options may not be available on your vehicle. Only the options available will be displayed on your driver information center (DIC). Oil Life Monitor Reset - Units Selection (English/Metric) - Remote Start Capability - Horn Chirp During Remote Keyless Entry Locking - Horn Chirp During Remote Keyless Entry Unlocking - Exterior Light Flash During Remote Keyless Entry Locking or Unlocking - Delayed Locking - Automatic Vehicle Unlocking: Specific Doors - Automatic Vehicle Unlocking: When Key is Off or When Shift To Park - Exterior Perimeter Lighting During Remote Keyless Entry Unlock - Security System Passive or Remote Keyless Entry Arming - Select Language: (English, French, Spanish or German) When the desired option is reached, use the ENTER button to toggle between the modes of that option. To make a selection, press the MENU button again. If no selection is made within 10 seconds, the display will revert back to the previous information displayed. The MENU mode is exited when the INFO button is pressed, a 10 second time period has elapsed, the ignition is turned to OFF, or the end of the MENU list is reached. The following display messages may appear on your vehicles driver information center (DIC) by pressing the MENU button: Oil Life Reset: When this option is displayed you can reset the Oil Life Monitor system. To reset the system to 100 percent, press and hold the ENTER button for at least 1 second. An ACKNOWLEDGED display message will appear for 3 seconds or until the next button is pressed. This will tell you the system has been reset. Units: When UNITS appears on the display, press the ENTER button to move between Metric or English. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is English. If you choose English, all information will be displayed in English units. For example, distance in miles and fuel economy in miles per gallon is displayed. If you choose metric, all information will be displayed in metric units. For example, distance in kilometers and fuel economy in liters per 100 kilometers is displayed. The unit measurement will also change the trip odometer, temperature, and average fuel economy displays. Remote Start: The remote start feature, if equipped, can be enabled or disabled. When REMOTE START appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Lock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the LOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Unlock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When UNLOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is OFF. Light Flash: If your vehicle has remote keyless entry, this feature which allows the vehicle exterior perimeter lighting to flash every time the LOCK or UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LIGHT FLASH appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Delay Lock: The delayed locking feature, which delays the actual locking of the vehicle, can be enabled or disabled. When DELAY LOCK appears Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Page 13456 on the display, use the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Auto Unlk The automatic door unlocking feature, which allows the vehicle to automatically unlock certain doors, can be enabled or disabled. When AUTO UNLK appears on the display, use the ENTER button to move between: ALL, DRVR, or NONE. When you have made your choice, press and the MENU button to record your selection. The initial setting from the factory is ALL. Unlk: This feature determines when the automatic door unlocking will occur, when either the key is turned to OFF or the vehicle is shifted into PARK (P). When UNLK appears on the display, use the ENTER button to move between KEY OFF and SHIFT TO P. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is SHIFT TO P. EXT Lights: If your vehicle has remote keyless entry, this feature, which allows the vehicle exterior perimeter lighting to turn ON each time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When EXT LIGHTS appears on the display, use the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Security: If your vehicle has the remote keyless entry system, this feature allows you to select the method used to arm the vehicle security system. When SECURITY appears on the display, use the ENTER button to move between RKE and PASSIVE. When you have made your choice, press the MENU button to record your selection. See Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information. Language: To select your choice of language, use the ENTER button to move between the optional languages. The languages are English, French, German and Spanish. Choosing a language will display all of the information on the DIC in the desired language. When you have made your choice, press the MENU button for at least one second to record your selection. The initial setting from the factory is ENGLISH. Enter: The ENTER button is used to reset certain functions and turn OFF or acknowledge messages on the DIC display. The ENTER button also toggles through the options available in each personalization menu. RADIO PRESET WITH REMOTE KEYLESS ENTRY The vehicle may be equipped with a radio personalization feature. This feature allows you to store radio preset stations to the remote keyless entry transmitter used to unlock the doors. Two drivers can store different preset stations and the radio recalls the stored radio settings associated with a particular transmitter. When UNLOCK is pressed on the remote, the preset stations that the driver stored is recalled. Refer to Radio/Audio System Description and Operation in Radio, Stereo, and Compact Disc for more information about the radio. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13465 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13466 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13467 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13468 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13469 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13470 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13471 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13472 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13473 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13474 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13475 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13478 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13479 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13480 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13481 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13482 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13483 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13484 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13485 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13486 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13487 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13488 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13489 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13490 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13491 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13492 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13493 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13494 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13495 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13496 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13497 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13498 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13504 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13509 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13515 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 13524 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13533 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13534 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13535 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13536 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13537 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13538 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13539 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13540 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13541 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13542 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13543 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13544 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13545 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13546 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13547 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13548 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13549 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13550 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13551 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13552 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13553 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13554 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13555 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13556 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13557 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13558 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13563 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13564 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13565 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13566 Diagnostic Tips Review Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13567 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13568 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13569 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13570 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13571 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13572 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13573 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13574 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13575 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13576 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13577 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13578 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13579 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13580 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13585 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13586 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13587 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13588 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13589 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13590 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13591 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13592 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13593 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13594 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13595 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13598 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13599 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13600 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13601 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13602 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13603 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13604 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13605 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13606 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13607 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13608 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13609 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13610 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13611 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13612 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13613 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13614 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13615 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13616 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13617 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13618 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13623 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13624 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13625 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13626 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13627 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13628 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13629 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13630 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13631 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13632 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13633 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13634 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13639 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13656 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-07-30-004G > May > 10 > A/T Various Concerns With Shifter And/Or Ignition Key Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-07-30-004G > May > 10 > A/T Various Concerns With Shifter And/Or Ignition Key > Page 13666 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 13676 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13685 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13686 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13687 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13688 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13689 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13690 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13691 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13692 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13693 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13694 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13695 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13696 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13697 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13698 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13699 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13700 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13701 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13702 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13703 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13704 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13705 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13706 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13707 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13708 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13709 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13710 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13715 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13716 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13717 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13718 Diagnostic Tips Review Table Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13719 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13720 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13721 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13722 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13723 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13724 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13725 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13726 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13727 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13728 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13729 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13730 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13731 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13732 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13737 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13738 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13739 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13740 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13741 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13742 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13743 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13744 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13745 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13746 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13747 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13748 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13749 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13750 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13751 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13752 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13753 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13754 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13755 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13756 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13757 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13758 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13759 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13760 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13761 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13762 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13763 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13764 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13765 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13766 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13767 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13768 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13769 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13770 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13775 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13776 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13777 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13778 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13779 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13780 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13781 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13782 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13783 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13784 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13785 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13786 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 13791 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions Amplifier: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13813 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13815 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13816 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13817 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13818 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13819 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13820 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13821 Amplifier: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13822 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13823 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13824 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13825 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13826 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13827 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13828 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13829 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13830 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13831 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13832 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13833 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13834 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13835 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13836 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13837 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13838 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13839 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13840 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13841 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13842 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13843 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13844 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13845 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13846 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13847 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13848 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13849 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13850 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13851 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13852 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13853 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13854 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13855 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13856 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13857 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13858 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13859 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13860 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13861 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13862 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13863 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13864 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13865 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13866 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13867 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13868 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13869 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13870 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13871 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13872 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13873 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13874 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13875 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13876 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13877 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13878 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13879 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13880 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13881 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13882 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13883 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13884 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13885 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13886 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13887 Amplifier: Electrical Diagrams Audio Amplifier C1 (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Diagram Information and Instructions > Page 13888 Audio Amplifier C2 (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 13889 Amplifier: Service and Repair AMPLIFIER REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams Remote Control: Diagrams Steering Wheel Controls Left (With RPO Code UK3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 13898 Steering Wheel Controls Right (With RPO Code UK3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Audio System - Revised Door Speaker Replacement Speaker: Technical Service Bulletins Audio System - Revised Door Speaker Replacement Bulletin No.: 05-08-44-034 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Speaker Replacement - Front Door and Front Upper Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Speaker Replacement - Front Door and Speaker Replacement - Front Upper procedures in the Entertainment sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Audio System - Revised Door Speaker Replacement > Page 13903 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Audio System - Revised Door Speaker Replacement > Page 13904 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door Speaker: Diagrams LF Door Speaker - LF Door (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13907 Speaker - LF Door (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13908 Speaker - LF Door Tweeter (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13909 Speaker: Diagrams LR Speaker - LR (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13910 Speaker - LR (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13911 Speaker: Diagrams RF Door Speaker - RF Door (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13912 Speaker - RF Door (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13913 Speaker: Diagrams Speaker - LF Door (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13914 Speaker - LF Door (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13915 Speaker - LF Door Tweeter (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13916 Speaker - LR (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13917 Speaker - LR (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13918 Speaker - RF Door (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13919 Speaker - RF Door (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13920 Speaker - RF Door Tweeter (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13921 Speaker - RR (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13922 Speaker - RR (With RPO Code UQ4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > LF Door > Page 13923 Speaker - Subwoofer (With RPO Code UQ3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Replacement Speaker: Service and Repair Door Speaker Replacement The content of this article reflects the changes identified in TSB Bulletin No. #05-08-44-034 dated October 21,2005. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Replacement > Page 13926 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Replacement > Page 13927 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Replacement > Page 13928 Speaker: Service and Repair Rear Compartment SPEAKER REPLACEMENT-REAR COMPARTMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Replacement > Page 13929 Speaker: Service and Repair Rear SPEAKER REPLACEMENT - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13935 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13936 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13937 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13938 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13939 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13940 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13941 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13942 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13943 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13944 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13945 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13946 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13947 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13948 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13949 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13950 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13951 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13952 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13953 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13954 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13955 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13956 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13957 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13958 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13959 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13960 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13961 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13962 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13963 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13964 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13965 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13966 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13967 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13968 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13969 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13970 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13971 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13972 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13973 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13974 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13975 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13976 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13977 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13978 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13979 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13980 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13981 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13982 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13983 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13984 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13985 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13986 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13987 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13988 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13989 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13990 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13991 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13992 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13993 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13994 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13995 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13996 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13997 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13998 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13999 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14000 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14001 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14002 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14003 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14004 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14005 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14006 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14007 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14008 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14017 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14018 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14019 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14020 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14021 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14022 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14023 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14024 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14025 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14026 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14027 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14028 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14029 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14030 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14031 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14032 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14033 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14034 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14035 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14036 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14037 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14038 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14039 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14040 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14041 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14042 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14043 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14044 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14045 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14046 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14047 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14048 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14049 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14050 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14056 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14061 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14066 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14067 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14073 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14082 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14083 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14084 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14085 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14086 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14087 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14088 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14089 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14090 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14091 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14092 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14093 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14094 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14095 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14096 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14097 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14098 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14099 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14100 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14101 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14102 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14103 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14104 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14105 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14106 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14107 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14112 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14113 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14114 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14115 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14116 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14117 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14118 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14119 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14120 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14121 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14122 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14123 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14124 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14125 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14126 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14127 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14128 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14129 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14130 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14131 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14132 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14133 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14134 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14135 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14136 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14137 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14138 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14139 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14140 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14141 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14142 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14143 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14144 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14145 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14150 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14151 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14152 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14153 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14154 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14155 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14156 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14157 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14158 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14159 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14160 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14161 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 14166 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14179 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14184 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14185 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14191 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14200 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14201 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14202 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14203 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14204 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14205 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14206 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14207 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14208 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14209 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14210 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14211 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14212 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14213 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14214 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14215 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14216 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14217 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14218 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14219 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14220 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14221 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14222 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14223 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14224 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14225 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14230 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14231 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14232 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14233 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14234 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14235 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14236 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14237 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14238 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14239 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14240 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14241 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 14246 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14259 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14264 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14265 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14275 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14276 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14277 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14278 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14279 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14280 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14281 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14282 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14283 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14284 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14285 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14286 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14287 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14288 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14289 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14290 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14291 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14292 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14293 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14294 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14295 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14296 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14297 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14298 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14299 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14300 Circuit/System Testing Component Testing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14305 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14306 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14307 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14308 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14309 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14310 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14311 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14313 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14314 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14315 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14316 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14317 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14318 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14319 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14320 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14321 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14322 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14323 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14324 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14325 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14326 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14327 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14328 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14329 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14330 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14331 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14332 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14333 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14334 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14335 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14336 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14337 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14338 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14343 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14344 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14345 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14346 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14347 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14348 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14349 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14350 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14351 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14352 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14353 Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14354 Labor Time Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 14359 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations Rear Compartments And Shelf Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 14371 Global Positioning System Module: Diagrams Vehicle Communication Interface Module (VCIM) C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 14372 Vehicle Communication Interface Module (VCIM) C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 14373 Vehicle Communication Interface Module (VCIM) C3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Locations > Page 14374 Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14383 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14384 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14385 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14391 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14392 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14393 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14402 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14403 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14404 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14410 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14411 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14412 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14422 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14423 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14424 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14425 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14426 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14427 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14428 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14429 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14430 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14431 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14432 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14433 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14434 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14435 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14436 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14437 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14438 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14439 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14440 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14441 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14442 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14443 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14444 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14445 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14446 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14447 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14448 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14449 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14450 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14451 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14452 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14453 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14454 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14455 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14456 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14457 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14458 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14459 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14460 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14461 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14462 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14463 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14464 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14465 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14466 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14467 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14468 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14469 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14470 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14471 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14472 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14473 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14474 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14475 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14476 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14477 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14478 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14479 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14480 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14481 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14482 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14483 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14484 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14485 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14486 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14487 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14488 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14489 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14490 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14491 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14492 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14493 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14494 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14495 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 14496 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14502 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14503 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14504 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14505 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14506 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 14507 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 14518 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Body Control Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 14528 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-002 > Nov > 09 > Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14534 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14537 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14538 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14539 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14540 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14541 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14542 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14543 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14544 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14545 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14546 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14547 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14548 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14549 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14550 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14551 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14552 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14553 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14554 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14555 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14556 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14557 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14558 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14559 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14560 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14561 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14562 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14563 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14564 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14565 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14566 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14567 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14568 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14569 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14570 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14571 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14572 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14573 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14574 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14575 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14576 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14577 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14578 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14579 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14580 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14581 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14582 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14583 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14584 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14585 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14586 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14587 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14588 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14589 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14590 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14591 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14592 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14593 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14594 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14595 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14596 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14597 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14598 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14599 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14600 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14601 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14602 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14603 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14604 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14605 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14606 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14607 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14608 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14609 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14610 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14611 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14612 Body Control Module (BCM) C1 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14613 Body Control Module (BCM) C1 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14614 Body Control Module (BCM) C2 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14615 Body Control Module (BCM) C2 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14616 Body Control Module (BCM) C2 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14617 Body Control Module (BCM) C3 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14618 Body Control Module (BCM) C3 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14619 Body Control Module (BCM) C3 Part 3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14620 Body Control Module (BCM) C4 Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14621 Body Control Module (BCM) C4 Part 2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System Body Control Module: Description and Operation Body Control System BODY CONTROL SYSTEM DESCRIPTION AND OPERATION The body control module (BCM) has a bussed electrical center integrated into the housing. Body control relays and fuses are installed directly on the BCM, which simplifies wiring and junction blocks on the vehicle. The body control system consists of the BCM and its associated controls. Battery positive voltage is provided to the BCM from IBCM BATT 1 fuse and the IBCM BATT 2 fuse in the underhood fuse block. The module grounds are wired to ground G201, G203 and G305. The BCM is wired to the GMLAN High speed serial data buss, and the GMLAN Low speed serial data buss, as well as discrete input and output terminals to control the functions of the vehicle's body. Serial Data Gateway The body control module (BCM) in this vehicle functions as a translator between the High and Low speed GMLAN busses. The 2 communication protocols use the BCM to translate communicated serial data messages between the control modules over the 2 serial data busses. Power Mode Master This vehicles BCM functions as the Power Mode Master (PMM). Refer to Power Mode Description and Operation for a complete description of power mode functions. Body Control Module The various body control module (BCM) input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The BCM functions include the following: A/C compressor request-Refer to Air Temperature Description and Operation in HVAC Systems Manual. - A/C cooling fan-Refer to Air Delivery Description and Operation in HVAC Systems - Manual. - Battery rundown protection (inadvertent power)-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Bulb check-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Chimes-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. Check gages - Door ajar warning - Headlamps ON - Key-in-ignition - Oil reset - Park brake warning - Seat belt not fastened - Turn signal ON - Door lock interface-Refer to Power Door Locks Description and Operation in Doors. - Electronic power steering (EPS)-Refer to Power Steering System Description and Operation in Power Steering System. - Engine coolant level sensing-Refer to Cooling System Description and Operation in Cooling System. - Exterior and interior lighting control-Refer to Exterior Lighting Systems Description and Operation in Lighting Systems. Automatic lighting control - Daytime running lamps (DRL) - Fog lamps - Park brake lights - Turn hazard lamps - Gage control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Horn interface-Refer to Horns System Description and Operation in Horns. - Instrument cluster indicator control-Refer to Instrument Panel Cluster (IPC) Description and Operation in Instrument Panel, Gages, and Console. - Interior lighting-Refer to Interior Lighting Systems Description and Operation in Lighting Systems. - Key-in-ignition sensing-Refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console. - Parking brake state sensing-Refer to Brake Warning System Description and Operation in Hydraulic Brakes. - Retained accessory power (RAP)-Refer to Retained Accessory Power (RAP) Description and Operation. - Rear compartment interface-Refer to Power Door Locks Description and Operation in Doors. - Rear defogger-Refer to Rear Window Defogger Description and Operation in Heated Glass Element. - Remote function control-Refer to Keyless Entry System Description and Operation in Keyless Entry. - Seat belt use sensing-Refer to Seat Belt System Description and Operation in Seat Belts. - Content theft deterrent-Refer to Theft Systems Description and Operation in Theft Deterrent. - Vehicle theft deterrent-Refer to Vehicle Theft Deterrent (VTD) Description and Operation in Theft Deterrent. - Washer solvent level sensing-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. - Wiper/washer-Refer to Wiper/Washer System Description and Operation in Wipers/Washer Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 14624 Body Control Module: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation for more information about the gateway. The powertrain control module (PCM) on this vehicle, uses a class 2 serial data buss. The class 2 buss is only used for diagnostics and the service programming system (SPS). During normal vehicle operations, there is no communications over the class 2 serial data buss. Normal vehicle operational messaging for the PCM is sent over the PCMs GMLAN high speed serial data buss. GMLAN HIGH SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. NOTE: a loss of serial data DTC does not represent a failure of the module that the code is set in. GMLAN LOW SPEED CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pules is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. CLASS 2 CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data circuit. Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7 volts nominal and inactive at ground potential. When the ignition switch is in RUN, and a scan tool is connected to the DLC, the powertrain control module (PCM) will start communicating diagnostic information over the class 2 serial data circuit. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Pin 1 GMLAN low speed communications terminal - Pin 2 Class 2 signal terminal - Pin 4 Scan tool power ground terminal - Pin 5 Common signal ground terminal - Pin 6 High speed GMLAN serial data bus (+) terminal - Pin 14 High speed GMLAN serial data bus (-) terminal - Pin 16 Scan tool power, battery positive voltage terminal CLASS 2 SERIAL DATA USAGE The class 2 serial data communications circuit on this vehicle is only used for powertrain control module (PCM) diagnostics and PCM service programming system (SPS) programming. SERIAL DATA REFERENCE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 14625 The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 14626 Body Control Module: Description and Operation Power Mode POWER MODE DESCRIPTION AND OPERATION Power to many of this vehicle's circuits are controlled by the module that is designated the Power Mode Master (PMM). This vehicle's PMM is the Body Control Module (BCM). The PMM controls which power mode (Run, Accessory, Crank, Retained Accessory Power, or Off) is active. Serial Data Power Mode Master On vehicles that have several control modules connected by serial data circuits, one module is the power mode master (PMM). On this vehicle, the PMM is the body control module (BCM). The PMM receives 3 discrete ignition switch signals to differentiate which power mode will be sent over the Serial Data circuits. The 3-wire Ignition Switch table illustrates the state of these inputs in correspondence to the ignition switch position. Relay Controlled Power Mode The body control module (BCM) uses the discrete ignition switch inputs Off/Run/Crank, Accessory, and ignition 1, to distinguish the correct power mode. The ignition 1 circuit is also routed to the Run/Crank relay for relay controlled power feeds during the appropriate power mode. The BCM, after determining the desired power mode, will activate the appropriate relays for that power mode. Run/Crank Relay The run/crank relay control circuit is connected to a constant ground and is switched by the ignition 1 circuit or the body control module (BCM). The BCM, will in lieu of the ignition switch position, activate the Run/Crank relay during a remote start event. The Run/Crank relay supplies a power signal to the following circuits, when the a Run or Crank power mode is selected: Automatic transmission shift indicator - Automatic transmission (A/T) - Switched power feeds to the BCM - Electronic brake control module (EBCM) - Electronic ignition module (spark control) - Electronic power steering module (EPS) - Fuel injectors - Powertrain control module (PCM) - Park neutral position (PNP) switch Accessory (ACC) Relay The adaptive cruise control (ACC) relay is energized when the Run or accessory power mode has been selected. The relay uses a Hot At All Times B+ power source derived from the underhood electrical center. The ACC relay is also energized by the body control module (BCM) to supply power during the retained accessory power (RAP) mode. The following devices are controlled by this relay: Inside rearview mirror - Heated seats - Power windows - Sunroof - Wiper washers switch Fail-Safe Operation Since the operation of the vehicle systems depends on the power mode, there is a fail-safe plan in place should the power mode master (PMM) fail to send a power mode message. The fail-safe plan covers those modules, using exclusively serial data control of power mode, as well as those modules with discrete ignition signal inputs. Serial Data Messages The modules that depend exclusively on serial data messages for power modes stay in the state dictated by the last valid power mode master (PMM) message until they can check for the engine run flag status on the serial data circuits. If the PMM fails, the modules monitor the serial data circuit for Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 14627 the engine run flag serial data. If the engine run flag serial data is True, indicating that the engine is running, the modules fail-safe to RUN. In this state, the modules and their subsystems can support all operator requirements. If the engine run flag serial data is False, indicating that the engine is not running, the modules fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. Discrete Ignition Signals Those modules that have discrete ignition signal inputs, also remain in the state dictated by the last valid power mode master (PMM) message received on the serial data circuits. They then check the state of their discrete ignition input to determine the current valid state. If the discrete ignition input is active, battery positive voltage, the modules will fail-safe to the RUN power mode. If the discrete ignition input is not active, open or 0 volts, the modules will fail-safe to OFF-AWAKE. In this state, the modules are constantly checking for a change status message on the serial data circuits and can respond to both local inputs and serial data inputs from other modules on the vehicle. BCM Wake-Up/Sleep States The body control module (BCM) is able to control or perform all of the BCM functions in the wake-up state. The BCM enters the sleep state when active control or monitoring of system functions has stopped, and the BCM has become idle again. The BCM must detect certain wake-up inputs before entering the wake-up state. The BCM monitors for these inputs during the sleep state, where the BCM is able to detect switch transitions that cause the BCM to wake-up when activated or deactivated. Multiple switch inputs are needed in order to sense both the insertion of the ignition key and the power mode requested. The BCM will enter a wake-up state, if any of the following wake-up inputs are detected: Activity on the serial data line - Detection of a battery disconnect and reconnect condition - Headlamps are ON. - Ignition is turned ON. - Key-in-ignition switch - Park lamps are ON. - RFA message The BCM will enter a sleep state when all of the following conditions exist: The ignition switch is OFF. - No activity exists on the serial data line. - No outputs are commanded. - No delay timers are actively counting. - No wake-up inputs are present. If all these conditions are met, the BCM will enter a low power or sleep condition. This condition indicates that the BCM, which is the power mode master (PMM) of the vehicle, has sent an OFF or OFF-ASLEEP message to the other systems on the serial data line. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control System > Page 14628 Body Control Module: Description and Operation Retained Accessory Power (RAP) RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the retained accessory power (RAP) power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The Radio uses an exclusive RAP message that can not be circumvented by any door but the drives door. The BCM then sends a serial data power mode message ending the RAP function. The radio is the only module that is controlled by the serial data circuits. RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) The body control module (BCM) keeps the accessory relay energized during all power modes, except Off-Awake and Crank. The devices powered by the accessory relay during the retained accessory power (RAP) power mode are the sunroof and windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Body Control Module: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information: - The identification of the control modules which are not communicating. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14631 Body Control Module: Symptom Related Diagnostic Procedures A Symptoms - Computer/Integrating Systems SYMPTOMS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: - Data Link Communications Description and Operation - Body Control System Description Retained Accessory Power (RAP) Description and Operation Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Scan Tool Does Not Power Up See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with Class 2 Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures - Scan Tool Does Not Communicate with High Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With High Speed GMLAN Device - Scan Tool Does Not Communicate with Low Speed GMLAN Device See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Symptom Related Diagnostic Procedures/Scan Tool Does Not Communicate With Low Speed GMLAN Device - Retained Accessory Power (RAP) On After Timeout See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative See: Diagnosis By Symptom Computer/Integrating Systems/Retained Accessory Power (RAP) Inoperative Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14632 Steps 1-12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14633 Steps 13-17 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14634 Steps 1-12 Power Mode Mismatch POWER MODE MISMATCH CIRCUIT DESCRIPTION Normal vehicle serial data communications and the control modules operations will not begin until the system power mode has been identified. Discrete wires from the ignition switch contacts are monitored by a module which acts as the power mode master (PMM) in order to determine the correct power mode. The module which is the PMM communicates the system power mode to all modules on the serial data lines. Refer to Body Control System Description and Operation to identify which module is the PMM and the applicable power mode look up table. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14635 Steps 1-6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14636 Steps 7-14 The numbers below refer to the step numbers on the diagnostic table. 6. This step tests for battery voltage on the incorrect signal circuits. 7. This step tests for no battery voltage on the required signal circuits. 8. If any ignition switch parameters that should be inactive in the present ignition switch position are active, 2 ignition switch signal circuits may be shorted together. 9. This step eliminates open circuits as the cause of the malfunction. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14637 Body Control Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Accessory Relay Command: The scan tool displays the state of the accessory relay command. Battery Voltage Signal: The scan tool displays the vehicle voltage. Ignition Mode Switch: The scan tool displays the ignition switch voltage signal. This signal is derived from the ignition Off/Run/Crank circuit. Ignition Switch Accessory: The scan tool displays the state of the ignition switch accessory circuit. Ignition Switch Run/Crank: The scan tool displays the state of the ignition switch Run/Crank circuit. Key In Ignition Cylinder: The scan tool displays whether or not the key is in the ignition cylinder. Power Mode: The scan tool displays the vehicle power mode. Run Relay Command: The scan tool displays the state of the Run relay. Run Crank Relay Command: The scan tool displays the state of the Run Crank relay. Vehicle Control Systems Data BCM Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. A new body control module (BCM) must be programmed with the proper regular production option (RPO) configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. The Tech 2 software will automatically prompt you with the RPO available for the vehicle. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the Vehicle Control Systems in Computer/Integrating Systems menu on the scan tool to program the BCM. Select Module Replacement/Setup and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passkey 3 Programming Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passkey 3 Programming procedure. Perform the Passkey 3 Programming Procedure if any of the following components have been replaced: The BCM - The powertrain control module (PCM)Refer to Programming Theft Deterrent System Components in Theft Deterrent for the proper procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 14640 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair Front Bumper Impact Bar Bracket Replacement Removal Procedure CAUTION: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR. 2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair as much of the damage as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Note the number and location of the factory welds for installation of the impact bar bracket - front bumper Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair > Page 14646 6. Locate and drill out all the factory welds from the outside surface of the rail. 7. Remove the front bumper impact bar bracket. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Verify the location of the front rail using 3-dimensional measuring equipment. 3. Position the impact bar bracket on the rail and clamp in place. 4. Plug weld accordingly. 5. Clean and prepare all of the welded surfaces. 6. Install all of the related panels and components. 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 8. Paint the repaired area. 9. Connect the negative battery cable. 10. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement - Front Bumper - Upper (Chevy) Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement - Front Bumper Upper (Chevy) Fascia Grille Replacement - Front Bumper - Upper (Chevy) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement - Front Bumper - Upper (Chevy) > Page 14653 Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement - Front Bumper Upper (Pontiac) Fascia Grille Replacement - Front Bumper - Upper (Pontiac) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement - Front Bumper - Upper (Chevy) > Page 14654 Front Bumper Cover / Fascia: Service and Repair Fascia Deflector, Radiator Grille Replacement Front Lower Fascia Deflector, Radiator Grille Replacement - Front Lower Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement - Front Bumper - Upper (Chevy) > Page 14655 Front Bumper Cover / Fascia: Service and Repair Fascia, Fascia Energy Absorber, Impact Bar Replacement - Front Fascia, Fascia Energy Absorber, Impact Bar Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement - Front Bumper - Upper (Chevy) > Page 14656 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 14661 Front Bumper Reinforcement: Service and Repair Impact Bar Bracket Replacement - Front Bumper Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in Restraint Systems. 2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair as much of the damage as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Important: Note the number and location of the factory welds for installation of the impact bar bracket - front bumper Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 14662 6. Locate and drill out all the factory welds from the outside surface of the rail. 7. Remove the front bumper impact bar bracket. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 14663 Important: Verify the location of the front rail using 3-dimensional measuring equipment. 3. Position the impact bar bracket on the rail and clamp in place. 4. Plug weld accordingly. 5. Clean and prepare all of the welded surfaces. 6. Install all of the related panels and components. 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings. 8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings. 9. Connect the negative battery cable. 10. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in Restraint Systems. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair Rear Bumper Bracket: Service and Repair Impact Bar Anchor Plate Replacement - Rear Bumper Removal Procedure CAUTION: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR. 2. Disconnect the negative battery cable 3. Remove all related panels and components. 4. Repair as much of the damage as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Note the number and location of the factory welds for installation of the anchor plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair > Page 14668 6. Locate and drill out all the necessary factory welds. 7. Remove the anchor plate. Installation Procedure IMPORTANT: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair > Page 14669 4. Position the anchor plate to the rear rail. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repaired area. 10. Connect the negative battery cable 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) Rear Bumper Cover / Fascia: Service and Repair Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) > Page 14676 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) > Page 14677 Rear Bumper Cover / Fascia: Service and Repair Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Pontiac) Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Pontiac) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia, Fascia Energy Absorber, Impact Bar, Fascia Bracket Replacement - Rear (Chevy) > Page 14678 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Cabin Ventilation Grille: Customer Interest A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 14691 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Cabin Ventilation Grille: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop Bulletin No.: 05-08-57-002A Date: April 08, 2005 TECHNICAL Subject: Water on Passenger Floor/Blower Motor Inoperative (Install Deflector) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include a GM Part Number. Please discard Corporate Bulletin Numbers 05-08-57-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the front passenger floor is wet or the blower motor in inoperative. Cause This condition may be caused by water entering the fresh air inlet to the HVAC case. Correction 1. Remove the air inlet grille panel. 2. Remove the piece of foam strip or weatherstrip that may be attached to the top of the right hand air inlet opening. 3. Clean the sheet metal around the air inlet with a non-oil based cleaner. 4. Remove the paper backing from the deflector and install it to the air inlet opening with the adhesive side down. Refer to the illustration above. 5. Reinstall the air inlet grill panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 05-08-57-002A > Apr > 05 > A/C - Water Leaks Onto Passenger Floor/Blower Motor Inop > Page 14697 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Page 14698 Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Pull the hood rear seal from the air inlet grille panel to remove it. 2. Remove the wiper arms. 3. Remove the push pin fasteners in the air inlet grille panel. 4. Disconnect the washer fluid hose. 5. Remove the air inlet grille panel from the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 14703 6. Remove the washer nozzles from the air inlet grille panel. Installation Procedure 1. Install the washer nozzles to the air inlet grille panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 14704 2. Position the air inlet grille panel to the vehicle. 3. Connect the washer fluid hose. 4. Install the push pin fasteners to the air inlet grille panel. 5. Install the wiper arms. 6. Install the hood rear seal to the air inlet grille panel and press it into position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold Front Door Exterior Handle: Customer Interest Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold > Page 14717 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold Front Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold > Page 14723 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 14724 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 05-08-64-005 Date: 050209 Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 14725 Disclaimer Technical Service Bulletin # 05-08-64-005 Date: 050209 Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 14726 Warranty Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Page 14727 Front Door Exterior Handle: Service and Repair Door Handle Replacement - Front Outside Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel Front Door Interior Handle: Customer Interest Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14736 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14737 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14738 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative Front Door Interior Handle: Customer Interest Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14743 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14744 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14745 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel Front Door Interior Handle: All Technical Service Bulletins Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14751 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14752 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14753 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative Front Door Interior Handle: All Technical Service Bulletins Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14758 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14759 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14760 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-033 > Oct > 05 > Body - Revised Interior Door Handle Replacement Front Door Interior Handle: All Technical Service Bulletins Body - Revised Interior Door Handle Replacement Bulletin No.: 05-08-64-033 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Door Handle Replacement-Inside Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit This bulletin is being issued to revise the Door Handle Replacement-Inside procedure in the Doors sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 05-08-64-033 > Oct > 05 > Body - Revised Interior Door Handle Replacement > Page 14765 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > 05-08-64-033 > Oct > 05 > Body - Revised Interior Door Handle Replacement Front Door Interior Handle: All Technical Service Bulletins Body - Revised Interior Door Handle Replacement Bulletin No.: 05-08-64-033 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Door Handle Replacement-Inside Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit This bulletin is being issued to revise the Door Handle Replacement-Inside procedure in the Doors sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > 05-08-64-033 > Oct > 05 > Body - Revised Interior Door Handle Replacement > Page 14771 The information shown has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14772 Front Door Interior Handle: By Symptom Technical Service Bulletin # 05-08-64-036B Date: 060321 Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14773 3. Remove the door pull cup and switch plate. 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14774 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14775 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-036B Date: 060321 Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14776 discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14777 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14778 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14779 Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14780 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14781 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14782 Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14783 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14784 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14785 Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14786 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Interior Handle: > Page 14787 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Inside Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 14790 Front Door Interior Handle: Service and Repair Door Handle Components Door Handle Cable Replacement - Front Inside Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Recalls for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts Front Door Hinge: Recalls Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Recalls for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14799 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Recalls for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14800 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Recalls for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14801 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Recalls for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14802 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > By Symptom for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts Front Door Hinge: By Symptom Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > By Symptom for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14808 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > By Symptom for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14809 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > By Symptom for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14810 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > By Symptom for Front Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14811 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts Front Door Hinge: All Technical Service Bulletins Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14817 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14818 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14819 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14820 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Page 14821 Front Door Hinge: Service and Repair Hinge Replacement - Front Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Page 14822 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold Front Door Latch: Customer Interest Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold > Page 14831 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold Front Door Latch: All Technical Service Bulletins Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold > Page 14837 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 14838 Front Door Latch: By Symptom Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 14839 The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 14840 Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 14841 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair Door Check Link Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel Front Door Panel: Customer Interest Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14853 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14854 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14855 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel Front Door Panel: All Technical Service Bulletins Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14861 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14862 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 05-08-64-036B > Mar > 06 > Interior - Door Panel Trim Fabric Pulls Away From Panel > Page 14863 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 14869 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14870 Front Door Panel: By Symptom Technical Service Bulletin # 05-08-64-036B Date: 060321 Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14871 3. Remove the door pull cup and switch plate. 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14872 Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14873 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-036B Date: 060321 Interior - Door Panel Trim Fabric Pulls Away From Panel Bulletin No.: 05-08-64-036B Date: March 21, 2006 TECHNICAL Subject: Fabric On Door Trim Too Short (Replace Pull Cup With Wider Bezel Or Beauty Ring) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to include procedures for vehicles both with and without power window/locks and update the warranty information . Please Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14874 discard Corporate Bulletin Number 05-08-64-036A (Section 08 - Body and Accessories). Condition Some customers may comment that the fabric on the door trim is pulling away from the pull cup. Cause This may be due to the bezel on the pull cup. It is not wide enough to account for the variation in the water cut jet process on the trim panel. Correction Replace the pull cup with a new design cup that has a wider bezel following the procedure below. For vehicles without power windows and locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the pull cup. 4. Install the new pull cup with a wider bezel. 5. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the trim plate in the bottom of the pull cup. For vehicles with power windows and/or locks 1. Remove the trim plate in the bottom of the pull cup with a small screwdriver. 2. Remove the two screws. 3. Remove the door pull cup and switch plate. 4. Disconnect the electrical connectors. 5. Install the beauty ring under the pull cup and switch plate. 6. Install the electrical connectors. 7. Install the switch plate into the door panel. Use a plastic trim tool and hold the trim down in front as shown in the illustration above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14875 8. Install the two screws. Tighten Tighten the screw to 2 N.m (18 lb in). 9. Install the plate in the bottom of the pull cup. Parts Information Important: This part is NOT packaged in the quantity of two per pack. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 14876 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door Trim Panel Replacement - Side Front Door Trim Panel Replacement - Upper Extension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 14879 Trim Panel Replacement - Upper Extension Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 14880 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Striker Replacement - Door (Coupe) Front Door Striker: Service and Repair Striker Replacement - Door (Coupe) Striker Replacement - Door (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Striker Replacement - Door (Coupe) > Page 14885 Front Door Striker: Service and Repair Striker Replacement - Door (Sedan) Striker Replacement - Door (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Upper Auxiliary Weatherstrip Replacement - Front Door Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 14890 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening (Coupe) Weatherstrip Replacement - Door Opening (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 14891 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening (Sedan) Weatherstrip Replacement - Door Opening (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 14892 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 14898 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Inner Front Side Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 14899 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Power) Window Regulator Replacement - Front Door (Power) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 14904 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door (Manual) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 14905 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold Rear Door Exterior Handle: Customer Interest Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold > Page 14916 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold Rear Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 05-08-64-005 > Feb > 05 > Body - Outside Door Handle Sticks In Extreme Cold > Page 14922 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise Wheel Cover: All Technical Service Bulletins Tires/Wheels - Wheel Squeak Noise TECHNICAL Bulletin No.: 05-03-10-006D Date: June 02, 2010 Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with 15-Inch Wheel Covers Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 05-03-10-006C (Section 03 - Suspension). Condition Some customers may comment on a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h [0-15 mph]). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction Install insulator tape on the backside of all four wheel covers. Use the following procedure: Chevrolet Cobalt/Pontiac G5 Pontiac Pursuit Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > 05-03-10-006D > Jun > 10 > Tires/Wheels - Wheel Squeak Noise > Page 14928 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol (using a clean, lint-free, non-abrasive cloth) at the insulator locations. Refer to the illustrations above. 5. Cut forty 7 mm (0.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside at the outer most edge as shown in the illustrations above. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be 10 insulators placed on each wheel cover. Important Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information *To obtain this product, check your dealer's auto body shop - they may already have this tape. You may also contact the 3M(R) Automotive Aftermarket Helpline at 1-877-666-2277 and follow the menu options to locate a store near you where it can be purchased. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > Page 14929 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 05-08-64-005 Date: 050209 Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > Page 14930 Disclaimer Technical Service Bulletin # 05-08-64-005 Date: 050209 Body - Outside Door Handle Sticks In Extreme Cold Door Handle Sticks When Ambient Temperatures are Below 0 Degrees Celsius or 32 Degrees Fahrenheit (Lubricate Door Handle Pawl) # 05-08-64-005 - (Feb 9, 2005) Models: 2005 Buick LaCrosse, Allure (Canada Only) 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside door handle sticks. Cause This condition may be due to water freezing under the plastic sleeve on the door handle pawl causing an interference with the door handle operation. Correction Apply lubricant to the door handle of all the doors. Follow the steps below: Important: The vehicle must be at room temperature to avoid damaging the handle. 1. Pull the door handle to its full open position. 2. Move the plastic sleeve off the door handle pawl to expose the cavity in the pawl as seen in the illustration above. 3. With an acid brush, apply Synthetic Lubricant with Teflon to the top and bottom cavity in the pawl. 4. Install the plastic sleeve. Parts Information Parts are currently available from GMSPO. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > Page 14931 Warranty Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Page 14932 Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative Rear Door Interior Handle: Customer Interest Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14941 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14942 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14943 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative Rear Door Interior Handle: All Technical Service Bulletins Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14949 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14950 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 05-08-64-030A > Nov > 05 > Body - Interior Door Handle Clicking Noise/Inoperative > Page 14951 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14952 Rear Door Interior Handle: By Symptom Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14953 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14954 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14955 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14956 Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14957 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14958 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-030A Date: 051102 Body - Interior Door Handle Clicking Noise/Inoperative Bulletin No.: 05-08-64-030A Date: November 02, 2005 TECHNICAL Subject: Interior Door Handle Inoperative Or Clicking Noise Heard When Opening Door (Replace Interior Door Handle) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Supercede: This bulletin is being revised to add the Pontiac Pursuit. Please discard Corporate Bulletin Number 05-08-64-030 (Section 08 - Body and Accessories). Condition Some customer may comment that the door will not open from the inside or there is a clicking noise when the door is opened. The noise seems to come from the door handle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14959 Cause This condition may be caused because the cable barrel end to the door handle may not be seated properly, or the cable housing may not be properly seated. Correction Remove the door trim and inspect the handle. If the cable barrel is not seated in the handle, apply pressure to the cable to lock it in. If the handle is inoperative, replace the handle following the procedure below. 1. Place the door trim in your lap and with your thumbs on the back side of the handle, twist the top of the panel downward. This will cause the handle the come out the front. 2. Remove the glue with an Exacto blade. Important: It is not necessary to glue the top of the handle to the trim panel. It is done at the plant for shipping purposes only. 3. Install the handle in the door trim panel. Apply some pressure and it will snap in place. 4. Install the door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14960 Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 14961 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Page 14962 Rear Door Interior Handle: Service and Repair Door Handle Cable Replacement - Rear Inside Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Recalls for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts Rear Door Hinge: Recalls Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Recalls for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14971 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Recalls for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14972 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Recalls for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14973 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Recalls for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14974 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > By Symptom for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts Rear Door Hinge: By Symptom Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > By Symptom for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14980 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > By Symptom for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14981 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > By Symptom for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14982 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > By Symptom for Rear Door Hinge: > 05055 > May > 05 > Campaign Incorrect Door Hinge Bolts > Page 14983 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts Rear Door Hinge: All Technical Service Bulletins Campaign - Incorrect Door Hinge Bolts Incorrect Door Hinge Bolt # 05055 - (May 12, 2005) Models: 2005 Chevrolet Malibu, Malibu Maxx, Cobalt 2005 Pontiac Pursuit An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire. Condition Some vehicles may have been built with one or more incorrect door hinge bolts. Correction Inspect all door hinge bolts and replace as needed. Inspection Procedure 1. Open the front door. 2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number. - Hinge to body bolts with the grade 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14989 3. Repeat the inspection for all front door hinge to body bolts. Important: There are two hinge to body bolts per hinge. There are two hinges per door. 4. Inspect the rear door hinge to body bolts for the grade number. - Hinge to body bolts with the grade of 10.9 are correct and require no further action. - Hinge to body bolts with the grade 9.8 must be replaced. Front Door Bolt Replacement Procedure 1. Open and support the door. 2. Disconnect the rubber conduit from the A-pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14990 3. Disconnect the front door harness electrical connector. 4. Remove the bolt from the check link. 5. With an assistance, remove the door side hinge bolts. 6. With an assistant, remove the front door from the vehicle. 7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft) 8. With an assistant, position the front door to the hinges. 9. With an assistant, install the door hinge to front door bolts. Tighten ^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft). 10. Install the bolt to the check link. Tighten Tighten the check link bolt to 20 Nm (15 lb ft) 11. Connect the front door electrical harness. 12. Connect the rubber conduit to the A-pillar. 13. Remove the support from the front door. 14. Inspect the door for proper operation and alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14991 15. Repeat this procedure on the opposite side front door as required. Rear Door Bolt Replacement Procedure 1. Open the front door in order to remove the rear door hinge bolts.. 2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement. Tighten ^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft). ^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft) 3. Paint installed bolts with touch-up paint to match the body color. 4. Repeat this procedure on the opposite side rear door as required. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 05055 > May > 05 > Campaign - Incorrect Door Hinge Bolts > Page 14992 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 14993 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 14994 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold Rear Door Latch: Customer Interest Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold > Page 15003 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold Rear Door Latch: All Technical Service Bulletins Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 05-08-64-002B > Apr > 06 > Body - Door Latches Freezes in Extreme Cold > Page 15009 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 15010 Rear Door Latch: By Symptom Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 15011 The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 15012 Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 15013 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair Door Check Link Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 15021 Rear Door Panel: Service and Repair Power Window Switch Replacement - Rear Door Power Window Switch Replacement - Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 15022 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments Lock Striker Adjustment - Door Notice: Striker alignment is a crucial part of door latch operation. Do not use the door striker to adjust the door to the vehicle. Failure to properly adjust the striker can result in damage to the door latch and the striker. 1. Loosen the striker bolts (2). 2. Attach the striker bolts (2) snugly in order to ensure that the striker (1) is still movable. 3. Pull on the outside handle. 4. Gently push the door against the body in order to ensure that the striker (1) allows a flush fit. 5. Slowly open the door. Notice: Refer to Fastener Notice. 6. Tighten the bolts (2). Tighten the striker bolts (2) to 25 N.m (18 lb ft). 7. Touch up any exposed or unpainted surface on the lock pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement > Page 15034 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Manual Window Regulator Replacement - Rear Door (Manual) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 15042 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Power Window Regulator Replacement - Rear Door (Power) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement Fuel Door: Service and Repair Fuel Filler Door Replacement Fuel Filler Door Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement > Page 15047 Fuel Door: Service and Repair Fuel Filler Pocket Replacement Fuel Filler Pocket Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open the hood. 2. Place a suitable support between the hood and the air inlet grille panel. 3. Using a grease pencil, mark the position of the hood hinge. 4. Remove the front fender. 5. Remove the hinge bolts and the hinge. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 15052 1. Position the hood hinge to the alignment marks on the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hood hinge to body bolts. Tighten the hood hinge to body bolts to 10 N.m (89 lb in). 3. Install the front fender. 4. Remove the hood to air inlet grille panel support. 5. Slowly lower the hood. 6. Inspect the hood alignment. Align the hood if necessary. 7. Tighten the hinge to hood bolts. Tighten the hinge to hood bolts to 10 N.m (89 lb in). 8. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Raise the hood. 2. Remove the hood insulator push-in retainers (1) from the hood using the J 38778. 3. Slide the hood insulator rearward. Remove the hood insulator (2). Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Page 15056 1. Position the hood insulator (2) under the tabs that are located at the front and center of the hood. 2. Install the hood insulator push-in retainers (1) until fully seated. 3. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Latch Replacement Removal Procedure 1. Raise the hood. 2. Mark the hood latch location to the support bracket with a grease pencil. 3. Remove the hood latch bolts. 4. Disconnect the release cable from the hood latch by squeezing the cable retainer. 5. Remove the hood latch from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 15060 1. Install the hood latch release cable to the hood latch. 2. Position the hood latch to the alignment marks on the support bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the hood latch bolts. 4. Tighten the latch bolts with the latch in the full up position. 5. Slowly close the hood and press down until the hood is flush with the fenders. 6. Raise the hood. Tighten the bolts to 10 N.m (89 lb in). 7. Adjust the hood, if required. Refer to Hood Adjustment. 8. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Raise the hood. 2. Remove the release cable from the latch. Note the routing of the hood cable in the engine compartment for installation. 3. Tape a 2 m (7 ft) length of wire to the latch end of the cable. 4. Inside the vehicle, remove the left front carpet retainer. Refer to Carpet Retainer Replacement Front (Coupe) Carpet Retainer Replacement Front (Sedan) in Interior Trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 15064 5. Remove the handle from the hood latch handle bracket. Use 2 small flat-bladed tools to disengage the retainer clip. 6. Slide the handle rearward. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 15065 7. If the handle will not slide rearward, use pliers in the following steps: 1. Place one end of the pliers on the tab of the hood release lever base, near the bracket. 2. Place the other end of the pliers on the rearward edge of the bracket. 3. Squeeze the pliers. 4. If necessary, place a flat-bladed tool in the slot. 8. Pull the hood cable through the front of the dashboard. Use a flat-bladed tool to loosen the grommet. Installation Procedure 1. Tape the feeder wire onto the end of the new cable. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 15066 2. Use the feeder wire to pull the cable through the cowl grommet into the engine compartment. 3. Install the hood primary latch release cable through the hole in the instrument panel. 4. Remove the feeder wire from the hood release cable. 5. Install the hood release cable handle assembly onto the bracket. 6. Install the front carpet retainer. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 15067 7. Connect the hood release cable to the latch. 8. Inspect the hood latch cable for proper operation. 9. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Strut Rod Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Raise and support the hood. 2. Release the hood assist rod upper and lower retainer using a small flat-bladed tool. 3. Remove the hood assist rod (1) from the vehicle. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 15071 1. Press the hood assist rod (1) to the upper hood assist rod ball stud until fully seated. 2. Press the hood assist rod (1) onto the lower hood assist rod ball stud until fully seated. 3. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement - Side Removal Procedure 1. Open the hood. 2. Remove the hood side bumper (1) from the fender by sliding the bumper rearward. Installation Procedure 1. Install the hood side bumper (1) to the fender by sliding the bumper forward. 2. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Side Seal Replacement - Hood Rear Side Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal, located at the end of the plenum to hood seal, from the fender. 3. Remove the seal from the vehicle. 4. Clean any adhesive from the pinch-weld flange and hood hinge using 3M(TM) P/N 8984. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side > Page 15079 2. With the rear side hood seal butted to the plenum to hood seal, press the side hood seal until the adhesive is fully adhered. 3. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side > Page 15080 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Pull the hood rear seal from the air inlet screen. Installation Procedure 1. Position the hood rear seal to the vehicle. 2. Push the hood rear seal onto the air inlet screen in order to fully seat the seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Rear Compartment Latch Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 15085 Rear Compartment Lid Release Actuator Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 15089 Rear Compartment Lid Release Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair Hinge Replacement - Rear Compartment Lid Removal Procedure 1. Raise and support the rear compartment lid. 2. Remove the rear compartment hinge bolts (2) from the hinge. 3. Remove the compartment lid hinge nuts (1) from the decklid studs. 4. Remove the compartment lid hinge (3) from the vehicle. Installation Procedure 1. Position the rear compartment lid hinge (3) to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Page 15093 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment hinge nuts (1) to the studs on the decklid. Tighten the nuts to 10 N.m (89 lb in). 3. Install the rear compartment hinge bolts (2) to the hinge. Tighten the bolts to 10 N.m (89 lb in). 4. Adjust the rear compartment lid if necessary. Refer to Compartment Lid Adjustment - Rear. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Latch Replacement - Rear Compartment Lid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Rear Compartment Lid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Rear Compartment Lid Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Open and support the rear compartment lid. 2. Using a small flat bladed tool, release the clip retaining the rear compartment lid assist rod to the lower assist rod ball stud. 3. Using a small flat bladed tool, release the clip retaining the rear compartment assist rod to the upper assist rod ball stud. 4. Remove the rear compartment lid assist rod from the vehicle. Installation Procedure 1. Press the rear compartment lid assist rod onto the upper rear compartment lid assist rod ball stud. 2. Press the rear compartment lid assist rod onto the lower assist rod ball stud. 3. Ensure that both clips are fully seated on the rear compartment assist rod. 4. Close the rear compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Stop > Component Information > Service and Repair Trunk / Liftgate Stop: Service and Repair Overslam Bumper Replacement - Rear Compartment Lid Removal Procedure 1. Open the rear compartment. 2. Remove the outer bumper from the compartment lid by twisting the bumper counterclockwise. Installation Procedure 1. Install the outer bumper to the compartment lid by twisting the bumper clockwise. 2. Close the rear compartment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Rear Compartment Lid Removal Procedure 1. Mark around the striker with a grease pen to retain the position of the lock striker. 2. Remove the lock striker bolts (1). 3. Remove the lock striker from the rear compartment. Installation Procedure 1. Position the lock striker to the alignment marks. 2. Install and hand tighten the striker and bolts (1). 3. Slowly close the compartment lid. Inspect the striker alignment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Page 15109 Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the lock striker bolts (1). Tighten the rear compartment lid lock striker bolts to 10 N.m (89 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures Body Emblem: Procedures Emblem/Nameplate Repair Notice: Use of harsh chemicals when cleaning can damage exterior lamps. Suggested cleaners are a mild soap and water, or Varnish Makers and Painters (VM&P;) Naptha. VM&P; Naptha is a specific type of naptha and should not be substituted by any other naptha. 1. Wash the panel using soap and water. 2. Wipe the panel dry. 3. Use a clean rag and 3M General Purpose Adhesive Cleaner 08984 or the equivalent in order to wipe the panel and the adhesive side of the emblem/nameplate. 4. Use a clean rag and an alcohol/water mixture in order to remove residue from the following components: * The molding * The emblem * The nameplate Notice: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with Adhesive Cleaner. Wipe the tape and mating surface with a clean, soft cloth. If the tape is damaged, refer to Emblem/Nameplate Replacement. 5. Apply a length of masking tape or a magnetic strip as a guide, if needed. Notice: Use the minimum amount of adhesive required. Adhesive drips or squeeze-out may cause paint damage. 6. Apply a thin film of adhesive to the back of the emblem/nameplate. * The molding * The emblem * The nameplate 7. Press the piece into place. If you use the LOCTITE(TM) 414 adhesive GM P/N 1052621 (Canadian P/N 993365) or the equivalent, apply constant pressure to the molding for 30 seconds or until a firm bond has been made. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 15123 Body Emblem: Removal and Replacement Emblem Replacement - Grille (Chevy) Emblem Replacement - Grille (Chevy) Emblem/Nameplate Replacement - Door Emblem/Nameplate Replacement - Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 15124 Emblem/Nameplate Replacement - Rear Compartment Lid (Cobalt LS) Emblem/Nameplate Replacement - Rear Compartment Lid (Cobalt LS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 15125 Emblem/Nameplate Replacement - Rear Compartment Lid (Cobalt SS) Emblem/Nameplate Replacement - Rear Compartment Lid (Cobalt SS) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 15126 Emblem/Nameplate Replacement - Rear Compartment Lid (Pontiac Pursuit GT) Emblem/Nameplate Replacement - Rear Compartment Lid (Pontiac Pursuit GT) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 15127 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Pull the hood rear seal from the air inlet grille panel to remove it. 2. Remove the wiper arms. 3. Remove the push pin fasteners in the air inlet grille panel. 4. Disconnect the washer fluid hose. 5. Remove the air inlet grille panel from the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 15131 6. Remove the washer nozzles from the air inlet grille panel. Installation Procedure 1. Install the washer nozzles to the air inlet grille panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 15132 2. Position the air inlet grille panel to the vehicle. 3. Connect the washer fluid hose. 4. Install the push pin fasteners to the air inlet grille panel. 5. Install the wiper arms. 6. Install the hood rear seal to the air inlet grille panel and press it into position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Body Side (Four Door) Lower Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Four Door) Molding Replacement - Body Side (Four Door) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Body Side (Four Door) > Page 15137 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Two Door) Molding Replacement - Body Side (Two Door) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures Windshield Moulding / Trim: Procedures Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 15142 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 15143 Windshield Moulding / Trim: Removal and Replacement Windshield Reveal Molding Replacement Removal Procedure Important: The window reveal molding is an applied molding design that is separate from the window. The reveal molding may be replaced with the window as an assembly, or the reveal molding may be available as a separate part. The window molding can only be replaced by removing the window. The old molding can not be reused. 1. Remove the windshield. 2. Place the window on a clean prepared surface. 3. Remove the molding from the windshield using a razor scraper. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 15144 Important: Apply the window reveal moldings in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 2. Using a heat gun, ensure that the temperature of the window and the reveal molding is approximately 29-32°C (85-90°F). 3. Apply masking tape around the window, 8.5 mm (0.33 in) from the window edge (a), as a guide for locating the window reveal molding. 4. Remove the protective liner from the back of the window reveal molding. 5. Position the window reveal molding to the location tape. Press the molding to the mounting surface. 6. Apply equal pressure along the window reveal molding to uniformly bond the molding to the window. 7. Remove the tape from around the window. 8. Install the windshield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Fender Liner Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Liner Panel Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation Floor Pan Insulators Description Floor pan insulators have been designed for the higher floor pan temperatures. Higher temperatures result from the use of the catalytic converter in the exhaust system. If you remove or disturb any insulators when servicing the vehicle in the field, reinstall the insulators in the original sequence and location. Use the material specified for that particular location on the floor pan if you replace an insulator. Important: Ensure that the following materials meet the Motor Vehicle Safety Standard Number 302 for flammability. * Floor pan insulator (cerra blanket thermal) Consists of 10 mm (3/8 in) thick aluminum silica (type 1). * Floor pan insulator (amberlite) Consists of 10 mm (3/8 in) thick resinated fibers (type 2). * Floor pan insulator sheet (phenolic bonded fiberglass) 305 x 457 mm (12 x 18 in) cut to size (type 3) Types 1 and 2 have the following characteristics: * Rolled stock * Ordered by linear foot * Cut to fit When servicing or replacing interior insulators, observe the following instructions: * Install the insulators in the original position and sequence. Place the pieces close together in order to avoid gapping or overlapping. * Use the original part for the following reasons: - In order to determine the amount of replacement material required - As a template for cutting and fitting the new piece to the floor pan * When installing the insulator, do not enlarge the cutouts or holes. The cutouts or holes are used for the attachment of the interior components such as seats or seat belts. * Route the cross body harnesses for the following interior components over the floor pan insulators and into the original location: - The power seats - The lap belt warning light and alarm - The rear speakers Clip the cross body harnesses into place. * Do not apply the spray-on deadeners and trim adhesive to the top of the floor pan at the area located directly over the catalytic converter or muffler(s). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Replacement Tools Required * J 24319-B Steering Linkage and Tie Rod Puller * J 43631 Ball Joint Remover Removal Procedure 1. With the wheels in the straight ahead position, remove the key from the ignition switch. 2. Secure the cooling module to the upper body structure. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the front wheels from the vehicle. 5. Remove the left and right splash shields. 6. Remove the front transaxle mount to cradle through bolt. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15162 7. Remove the rear transaxle mount to frame bolts. 8. Remove both stabilizer link to stabilizer shaft nuts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15163 9. Remove both tie rod to steering knuckle nuts. 10. Use the J 24319-B to separate the outer tie rods from the steering knuckles. 11. Remove the intermediate steering shaft to steering gear pinch bolt and discard. Important: DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur. 12. Disconnect the intermediate steering shaft from the steering gear. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15164 13. Remove both lower control arm ball stud to steering knuckle pinch bolts. Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result. 14. Lower the lower control arms in order to disengage the steering knuckle. If necessary, use the J 43631. 15. Mark the frame to body position with a paint pen or permanent marker. 16. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame. 17. Use two 2 x 4's between the lift table and the frame and lift the table to the frame. 18. Slowly remove the frame bolts using the following sequence: 1. Remove the front frame bolts. 2. Partially unscrew the rear frame bolts exposing 25.4 mm (1.5 in) of bolt shank. 19. Slowly lower the lift table to the floor. 20. Continue with the following steps when replacing the frame: 1. Remove the steering gear from the frame. 2. Remove the stabilizer bar from the frame. 3. Remove the lower control arms from the frame. 4. Remove the radiator brackets from the frame. Installation Procedure 1. If replacing the frame, perform the following steps: 1. Install the radiator brackets to the frame. 2. Install the lower control arms to the frame. 3. Install the stabilizer bar to the frame. 4. Install the steering gear to the frame. 2. With the frame on the lift table, raise the frame to the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15165 3. Hand start all the frame bolts while aligning the frame to the paint marks. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the frame bolts. Tighten the bolts to 100 N.m plus 180 degrees (74 lb ft) plus 180 degrees. 5. Lower and remove the hydraulic table. 6. Connect the lower control arm to the steering knuckle. Important: The torque sequence must be followed in the order that is listed. 7. Install the ball joint pinch bolt and nut. 1. First Pass: Tighten the nut to 50 N.m (37 lb ft). 2. Reverse nut 3/4 turn 3. Second Pass: Tighten the nut to 50 N.m (37 lb ft) plus 30 degrees. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15166 Important: The front and rear transmission mounts must be allowed to settle with the through bolts loosened. 8. Hand start the front transaxle mount through bolt. 9. Loosen the rear transmission mount through bolt. 10. Tighten the rear transaxle mount to frame bolts. Tighten the rear bolts to 50 N.m (37 lb ft). 11. Tighten the front and rear transaxle mount through bolts in the following order. 1. Tighten the rear bolt to 100 N.m (74 lb ft). 2. Tighten the front bolt to 100 N.m (74 lb ft). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 15167 12. Install the outer tie rods to the steering knuckles. 13. Install the new outer tie rod to the knuckle nuts. Tighten the nuts to 20 N.m (15 lb ft) plus 180 degrees. 14. Connect the stabilizer links to the stabilizer shaft. 15. Connect the intermediate shaft to the steering gear. 16. Install a new intermediate shaft pinch bolt. Tighten the bolt to 25 N.m (18 lb ft). 17. Install the left and right splash shields. 18. Install the front wheels. 19. Lower the vehicle. 20. Road test the vehicle in order to test for the following conditions: * Steering leads or pulls-Refer to Measuring Wheel Alignment in Wheel Alignment. * Abnormal powertrain noise or vibration at idle - Refer to Checking Frame Alignment in Frame and Underbody. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Fascia Grille Replacement - Front Bumper - Upper (Chevy) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement (Coupe) Arm Rest: Service and Repair Armrest Bracket Replacement (Coupe) Armrest Bracket Replacement (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement (Coupe) > Page 15176 Arm Rest: Service and Repair Armrest Bracket Replacement (Sedan) Armrest Bracket Replacement (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement (Coupe) > Page 15177 Arm Rest: Service and Repair Armrest Pull Cup Replacement Armrest Pull Cup Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement (Coupe) > Page 15178 Arm Rest: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 15183 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 15184 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 15185 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 15186 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15189 Carpet: Removal and Replacement Carpet Retainer Replacement - Front (Coupe) Carpet Retainer Replacement - Front (Coupe) Carpet Retainer Replacement - Front (Sedan) Carpet Retainer Replacement - Front (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15190 Carpet Retainer Replacement - Rear Carpet Retainer Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15191 Carpet Replacement Carpet Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15192 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Console: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with 5 different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the I/P storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS The key code can be obtained from the 5-digit number on the key tag that accompanies the original master and valet keys. The 5-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and 5 key cut depths (2). Key cut positions are numbered 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to Programming Theft Deterrent System Components in Theft Deterrent. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments:With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. Refer to Programming Theft Deterrent System Components. LOCK CYLINDER TUMBLER OPERATION Each of the 4 cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The I/P storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the I/P storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses 7 of the 10 cut positions, 1 through 7. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Page 15196 1. Hold the cylinder (7) so that the side with 4 tumbler spring wells is facing up. IMPORTANT: The ignition lock cylinder tumblers (8) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder. 2. Insert tumbler springs (4) into the 5 spring wells. 3. The first tumbler to be loaded will be the 1st key cut position the first number in the key code. Install the first tumbler (8) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the 3 remaining tumblers on this side of the lock cylinder, key cut positions 3, 5, and 7. 5. Inspect for correct loading of the tumblers (8) by inserting the key into cylinder (7). The tumblers (8) should be flush with the outside diameter of the cylinder (7). 6. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. Remove the key. 7. Insert the tumbler springs (4) into the 3 spring wells. 8. Install the tumbler (8) for the key cut position 2 into the slot nearest to the front of the lock cylinder. 9. Install the 2 remaining tumblers, key cut positions 4 and 6 on this side of the lock cylinder. 10. Inspect for correct loading of the tumblers (8) by inserting the key into cylinder (7). The tumblers (8) should be flush with the outside diameter of the cylinder (7). 11. Lightly lubricate the tumbler (8) surfaces using the provided lubrication. 12. With the key inserted into the housing, rotate the cylinder (7) so that the side with the 4 tumblers is facing up. 13. Insert one retaining pin spring (3) and one retaining pin (2) into the hole located behind the 4 tumblers (8). CAUTION: Wear safety glasses in order to avoid eye damage. IMPORTANT: The retaining pin spring (3) and retaining pin (2) are not self retaining and must be held in place until the cylinder (7) is assembled into the case assembly (1). 14. Align the retaining lug on the cylinder (7) with the groove that extends the full length of the case assembly (1). 15. With the retaining pin (2) full depressed, install the cylinder (7) into the case (1) until the retaining pin (2) enters the case assembly (1). 16. Fully insert the cylinder (7), then rotate the cylinder (7) counter clockwise until the retaining pin snaps into place limiting the rotation. 17. Remove the key and install the illumination ring (6) onto the case assembly (1). 18. Install the theft deterrent module (5) over the illumination ring (6). ASSEMBLING AND CODING DOOR LOCK CYLINDER The front side door lock cylinder only uses 7 of the 10 cut positions, 4 through 10. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. 1. Hold the cylinder (9) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The front side door lock cylinder tumblers (10) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder, or until the cylinder (9) is assembled into the case assembly (11). 2. Insert tumbler springs (5) into the 4 spring wells. 3. Install the tumbler for key cut position 4 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 6, 8 and 10, on this side of the lock cylinder. 5. Inspect for correct loading of the tumblers (10) by inserting the key into cylinder (9). All of the tumblers should be flush with the outside diameter of the lock cylinder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Page 15197 6. Turn the cylinder (9) so that the side with 3 tumbler spring wells faces up. 7. Insert the tumbler springs (5) into the 3 spring wells. 8. Install the tumbler for key cut position 5 into the slot nearest the front of the lock cylinder. 9. Install the 2 remaining tumblers for key cut positions 7 and 9 on this side of the lock cylinder. 10. Inspect for correct loading of the tumblers (10) by inserting the key into cylinder (9). All of the tumblers should be flush with the outside diameter of the lock cylinder. 11. Lightly lubricate the tumbler (10) surfaces using the provided lubrication. 12. Hold the case assembly (11) with the pre-staked detent spring retainer facing downward. 13. Insert one detent spring (3) and one detent ball (4) into the hole located to the rear and inside of the case assembly (11). CAUTION: Wear safety glasses in order to avoid eye damage. 14. Insert the key into the lock cylinder. 15. Ensure the detent spring (3) and ball (4) are held in place until the cylinder is fully installed. Install the cylinder into the case assembly (11). The detent ball (4) will line up with the V-shaped groove on the rear of the cylinder. 16. Carefully remove the key, keeping the lock cylinder (9) inserted into the case assembly (11). 17. Insert one shutter spring (8) into each hole located on the front of the cylinder (9). 18. Install the shutter assembly (7) into the recessed area in the front of the cylinder (9). Ensure the ends of the pin on the shutter assembly (7) are positioned in the pin cavities located on the front face of the cylinder (9). 19. Install the lock cylinder cap (6) by aligning the 2 notches in the cap with the drain hole located on the bottom of the case assembly (11) and the corresponding feature on the top of the case assembly (11).Press the cap into place with light hand pressure. 20. Install the appropriate lever (2). 21. Install the retaining ring (12). 22. Snap the appropriate rod retainer (1) into the hole in the lever (2). ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 4 through 10. The tumbler positions alternate in adjacent locations from side to side with 4 on one side and 3 on the other. 1. Hold the cylinder (6) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The rear compartment lid lock cylinder tumblers (7) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder, or until the cylinder (6) is assembled into the case assembly (1). 2. Insert the tumbler springs (2) into the 4 spring wells. 3. Insert the tumbler (7) for key cut position 3 into the slot nearest to the front of the lock cylinder (6). 4. Install the 3 remaining tumblers, key cut positions 6, 8 and 10, on this side of the lock cylinder. 5. Inspect for correct loading of the tumblers (7) by inserting the key into cylinder (6). All of the tumblers should be flush with the outside diameter of the lock cylinder (6). 6. Turn the cylinder (6) so that the side with 3 tumbler spring wells faces up. 7. Insert the tumbler springs (7) into the 3 spring wells. 8. Install the tumbler (7) for key cut position 5 into the slot nearest to the front of the lock cylinder. 9. Install the 2 remaining tumblers, key cut positions 7 and 9, on this side of the lock cylinder. 10. Inspect for the correct loading of the tumblers (7) by inserting the key into the cylinder (6). All of the tumblers should be flush with the outside diameter of the lock cylinder (6). 11. Lightly lubricate the tumbler (7) surfaces using the provided lubrication. 12. Install the lock cylinder (6) into case assembly (1). 13. Carefully remove the key, keeping the lock cylinder (6) inserted into the case assembly (1). 14. Insert one shutter spring (5) into each hole located on the front of the cylinder (6). 15. Install the shutter assembly (4) into the recessed area in the front of the cylinder (6). Ensure the ends of the pin on the shutter assembly (4) are positioned in the pin cavities located on the front face of the cylinder (6). 16. Install the lock cylinder cap (3) by aligning the 2 notches in the cap with the drain hole located on the bottom of the case assembly (1) and the corresponding feature on the top of the case assembly (1).Press the cap into place with light hand pressure. ASSEMBLING AND CODING I/P STORAGE COMPARTMENT LOCK CYLINDER The I/P storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the I/P storage compartment lock to retain the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Page 15198 lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the I/P storage compartment lock cylinder and should come already installed in the cylinder. 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor Console: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15201 Console: Service and Repair Console Replacement - Front Floor Console Replacement - Front Floor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15202 Console: Service and Repair Cup Holder Replacement - Front Floor Console - Rear CUP HOLDER REPLACEMENT - FRONT FLOOR CONSOLE - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15203 Console: Service and Repair Cupholder Replacement - Front Floor Console CUPHOLDER REPLACEMENT - FRONT FLOOR CONSOLE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15204 Console: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Console Replacement - Front Floor Console Replacement - Front Floor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15205 Cup Holder Replacement - Front Floor Console - Rear CUP HOLDER REPLACEMENT - FRONT FLOOR CONSOLE - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15206 Cupholder Replacement - Front Floor Console CUPHOLDER REPLACEMENT - FRONT FLOOR CONSOLE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15207 Door Replacement - Console Compartment Door Replacement - Console Compartment Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15208 Extension Replacement - Floor Console - Side Extension Replacement - Floor Console - Side Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15209 Latch Replacement - Console Compartment Door Latch Replacement - Console Compartment Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15210 Plate Replacement-Front Floor Console Armrest Plate Replacement-Front Floor Console Armrest Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15211 Trim Plate Replacement - Console Front Trim Plate Replacement - Console Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15212 Trim Plate Replacement - Console Rear Trim Plate Replacement - Console Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 15213 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15219 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15220 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15221 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15222 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15223 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15224 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15225 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15226 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15227 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15228 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15229 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15230 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15231 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15232 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15233 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15234 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15235 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15236 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15237 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15238 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15239 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15240 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15241 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15242 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15243 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15244 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 15245 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Procedures Drink Holders: Procedures Cup Holder Replacement - Front Floor Console - Rear CUP HOLDER REPLACEMENT - FRONT FLOOR CONSOLE - REAR Cupholder Replacement - Front Floor Console CUPHOLDER REPLACEMENT - FRONT FLOOR CONSOLE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Procedures > Page 15250 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Procedures > Page 15251 Drink Holders: Removal and Replacement Cop holder Replacement - Front Floor Console Cup holder Replacement - Front Floor Console Cup Holder Replacement - Front Floor Console - Rear Cup Holder Replacement - Front Floor Console - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Procedures > Page 15252 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Description and Operation Glove Compartment: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with 5 different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the I/P storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS The key code can be obtained from the 5-digit number on the key tag that accompanies the original master and valet keys. The 5-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and 5 key cut depths (2). Key cut positions are numbered 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to Programming Theft Deterrent System Components in Theft Deterrent. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments:With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. Refer to Programming Theft Deterrent System Components. LOCK CYLINDER TUMBLER OPERATION Each of the 4 cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The I/P storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the I/P storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses 7 of the 10 cut positions, 1 through 7. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Description and Operation > Page 15256 1. Hold the cylinder (7) so that the side with 4 tumbler spring wells is facing up. IMPORTANT: The ignition lock cylinder tumblers (8) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder. 2. Insert tumbler springs (4) into the 5 spring wells. 3. The first tumbler to be loaded will be the 1st key cut position the first number in the key code. Install the first tumbler (8) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the 3 remaining tumblers on this side of the lock cylinder, key cut positions 3, 5, and 7. 5. Inspect for correct loading of the tumblers (8) by inserting the key into cylinder (7). The tumblers (8) should be flush with the outside diameter of the cylinder (7). 6. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. Remove the key. 7. Insert the tumbler springs (4) into the 3 spring wells. 8. Install the tumbler (8) for the key cut position 2 into the slot nearest to the front of the lock cylinder. 9. Install the 2 remaining tumblers, key cut positions 4 and 6 on this side of the lock cylinder. 10. Inspect for correct loading of the tumblers (8) by inserting the key into cylinder (7). The tumblers (8) should be flush with the outside diameter of the cylinder (7). 11. Lightly lubricate the tumbler (8) surfaces using the provided lubrication. 12. With the key inserted into the housing, rotate the cylinder (7) so that the side with the 4 tumblers is facing up. 13. Insert one retaining pin spring (3) and one retaining pin (2) into the hole located behind the 4 tumblers (8). CAUTION: Wear safety glasses in order to avoid eye damage. IMPORTANT: The retaining pin spring (3) and retaining pin (2) are not self retaining and must be held in place until the cylinder (7) is assembled into the case assembly (1). 14. Align the retaining lug on the cylinder (7) with the groove that extends the full length of the case assembly (1). 15. With the retaining pin (2) full depressed, install the cylinder (7) into the case (1) until the retaining pin (2) enters the case assembly (1). 16. Fully insert the cylinder (7), then rotate the cylinder (7) counter clockwise until the retaining pin snaps into place limiting the rotation. 17. Remove the key and install the illumination ring (6) onto the case assembly (1). 18. Install the theft deterrent module (5) over the illumination ring (6). ASSEMBLING AND CODING DOOR LOCK CYLINDER The front side door lock cylinder only uses 7 of the 10 cut positions, 4 through 10. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. 1. Hold the cylinder (9) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The front side door lock cylinder tumblers (10) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder, or until the cylinder (9) is assembled into the case assembly (11). 2. Insert tumbler springs (5) into the 4 spring wells. 3. Install the tumbler for key cut position 4 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 6, 8 and 10, on this side of the lock cylinder. 5. Inspect for correct loading of the tumblers (10) by inserting the key into cylinder (9). All of the tumblers should be flush with the outside diameter of the lock cylinder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Description and Operation > Page 15257 6. Turn the cylinder (9) so that the side with 3 tumbler spring wells faces up. 7. Insert the tumbler springs (5) into the 3 spring wells. 8. Install the tumbler for key cut position 5 into the slot nearest the front of the lock cylinder. 9. Install the 2 remaining tumblers for key cut positions 7 and 9 on this side of the lock cylinder. 10. Inspect for correct loading of the tumblers (10) by inserting the key into cylinder (9). All of the tumblers should be flush with the outside diameter of the lock cylinder. 11. Lightly lubricate the tumbler (10) surfaces using the provided lubrication. 12. Hold the case assembly (11) with the pre-staked detent spring retainer facing downward. 13. Insert one detent spring (3) and one detent ball (4) into the hole located to the rear and inside of the case assembly (11). CAUTION: Wear safety glasses in order to avoid eye damage. 14. Insert the key into the lock cylinder. 15. Ensure the detent spring (3) and ball (4) are held in place until the cylinder is fully installed. Install the cylinder into the case assembly (11). The detent ball (4) will line up with the V-shaped groove on the rear of the cylinder. 16. Carefully remove the key, keeping the lock cylinder (9) inserted into the case assembly (11). 17. Insert one shutter spring (8) into each hole located on the front of the cylinder (9). 18. Install the shutter assembly (7) into the recessed area in the front of the cylinder (9). Ensure the ends of the pin on the shutter assembly (7) are positioned in the pin cavities located on the front face of the cylinder (9). 19. Install the lock cylinder cap (6) by aligning the 2 notches in the cap with the drain hole located on the bottom of the case assembly (11) and the corresponding feature on the top of the case assembly (11).Press the cap into place with light hand pressure. 20. Install the appropriate lever (2). 21. Install the retaining ring (12). 22. Snap the appropriate rod retainer (1) into the hole in the lever (2). ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 4 through 10. The tumbler positions alternate in adjacent locations from side to side with 4 on one side and 3 on the other. 1. Hold the cylinder (6) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The rear compartment lid lock cylinder tumblers (7) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder, or until the cylinder (6) is assembled into the case assembly (1). 2. Insert the tumbler springs (2) into the 4 spring wells. 3. Insert the tumbler (7) for key cut position 3 into the slot nearest to the front of the lock cylinder (6). 4. Install the 3 remaining tumblers, key cut positions 6, 8 and 10, on this side of the lock cylinder. 5. Inspect for correct loading of the tumblers (7) by inserting the key into cylinder (6). All of the tumblers should be flush with the outside diameter of the lock cylinder (6). 6. Turn the cylinder (6) so that the side with 3 tumbler spring wells faces up. 7. Insert the tumbler springs (7) into the 3 spring wells. 8. Install the tumbler (7) for key cut position 5 into the slot nearest to the front of the lock cylinder. 9. Install the 2 remaining tumblers, key cut positions 7 and 9, on this side of the lock cylinder. 10. Inspect for the correct loading of the tumblers (7) by inserting the key into the cylinder (6). All of the tumblers should be flush with the outside diameter of the lock cylinder (6). 11. Lightly lubricate the tumbler (7) surfaces using the provided lubrication. 12. Install the lock cylinder (6) into case assembly (1). 13. Carefully remove the key, keeping the lock cylinder (6) inserted into the case assembly (1). 14. Insert one shutter spring (5) into each hole located on the front of the cylinder (6). 15. Install the shutter assembly (4) into the recessed area in the front of the cylinder (6). Ensure the ends of the pin on the shutter assembly (4) are positioned in the pin cavities located on the front face of the cylinder (6). 16. Install the lock cylinder cap (3) by aligning the 2 notches in the cap with the drain hole located on the bottom of the case assembly (1) and the corresponding feature on the top of the case assembly (1).Press the cap into place with light hand pressure. ASSEMBLING AND CODING I/P STORAGE COMPARTMENT LOCK CYLINDER The I/P storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the I/P storage compartment lock to retain the Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Description and Operation > Page 15258 lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the I/P storage compartment lock cylinder and should come already installed in the cylinder. 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Procedures Glove Compartment: Procedures Compartment Replacement - Instrument Panel (I/P) COMPARTMENT REPLACEMENT - INSTRUMENT PANEL (I/P) Storage Compartment Replacement - Instrument Panel (I/P) STORAGE COMPARTMENT REPLACEMENT - INSTRUMENT PANEL (I/P) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Procedures > Page 15261 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Procedures > Page 15262 Glove Compartment: Removal and Replacement Compartment Replacement - Instrument Panel (I/P) Compartment Replacement - Instrument Panel (I/P) Dampener Replacement - I/P Compartment Dampener Replacement - I/P Compartment Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Procedures > Page 15263 Storage Compartment Replacement - Instrument Panel (I/P) Storage Compartment Replacement - Instrument Panel (I/P) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Procedures > Page 15264 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection Technical Service Bulletin # 06221A Date: 070413 Campaign - Increase of Head Impact Protection Bulletin No.: 06221A Date: April 13, 2007 CUSTOMER SATISFACTION Subject: 06221A - Modification to Increase Head Impact Protection Models: 2005-2006 Chevrolet Cobalt Coupe 2006 Pontiac Pursuit Coupe Without Roof-Mounted Side Impact Airbags Supercede: THIS BULLETIN IS BEING REVISED TO UPDATE THE SERVICE PROCEDURE AND ADD LABOR OPERATIONS. PLEASE DISCARD CORPORATE BULLETIN 06221, ISSUED MARCH 2007. Condition GM recently improved the head impact protection in certain 2007 model year vehicles. This added protection will reduce the risk of injury if a front seat occupant's head were to impact a point near the attachment of the sun visor to the roof. GM is making similar changes to certain 2005-2006 Chevrolet Cobalt Coupe and 2006 Pontiac Pursuit Coupe vehicles that were built before these changes were implemented. Correction Dealers are to install an energy-absorbing device between the front headliner and the vehicle roof. Vehicles Involved Involved are certain 2005-2006 Chevrolet Cobalt Coupe and 2006 Pontiac Pursuit Coupe vehicles not equipped with optional roof-mounted side impact airbags and built within the VIN breakpoints shown. Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through GMintoNet Recall Reports. Dealers will not have a report available it they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15273 Parts Information Parts required to complete this program are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Inspection Determine if the vehicle is equipped with side impact air bags. Refer to GMVIS to verify vehicle content. If the vehicle is equipped with side impact air bags, do not perform the service procedure in this bulletin. No further action is required. Submit a claim for Vehicle is Equipped with Side Impact Air Bags, labor operation V1595 for 0.2. If the vehicle does not have side impact air bags, refer to the service procedure in this bulletin. Perform Steps 1-4 on the driver's side of the vehicle only. After performing Steps 1-4, the headliner will drop about 203 mm (8 in), which will provide adequate room to determine if the energy absorbing (EA) piece has been installed. If either the interim production or current production/service repair have been performed, re-install the headliner, A-pillar trim panel, and sunshade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15274 Submit a claim for Inspect Vehicle to Determine if Energy Absorbing Device is Installed, labor operation V1596 for 0.4. If the production repair has not been performed, complete the service procedure in this bulletin. Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Submit a claim for Install Energy Absorbing Device, labor operation V1557 for 0.7. Service Procedure Tools Required Hot Glue Gun Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Remove the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. Remove the sunshades from the vehicle. Refer to Sunshade Replacement in SI. Remove the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. Remove the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece into the headliner. Use hot melt adhesive sticks to glue the EA plastic piece into the headliner. Locate the installation anchor points (2) for installing the energy absorbing (EA) plastic piece (3) onto the headliner (1). Apply hot glue to the energy absorbing (EA) plastic piece. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15275 Ensure that the energy absorbing (EA) plastic piece is installed properly. The tail ends of the energy absorbing (EA) plastic piece (2) should wrap around the anchor posts (1) of the headliner material. The body of the EA plastic piece should be firmly attached to the headliner. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades. Install the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. Install the sunshades. Refer to Sunshade Replacement in SI. Install the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. Install the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15276 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15277 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance Technical Service Bulletin # 06217A Date: 070404 Recall - Head Impact Non-Compliance Subject: FMVSS Noncompliance - Head Impact Protection # 06217A - (04/04/2007) Models: 2005-2006 Chevrolet Cobalt Coupe Without Roof-Mounted Side Impact Airbags THIS BULLETIN IS BEING REVISED TO UPDATE THE SERVICE PROCEDURE AND ADD LABOR OPERATIONS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 06217, ISSUED MARCH 2007. Condition General Motors has decided that certain 2005-2006 Chevrolet Cobalt Coupe vehicles not equipped with optional roof-mounted side impact airbags fail to conform to Federal Motor Vehicle Safety Standard 201, "Occupant Protection in Interior Impact". In tests at an impact point near the attachment of the sun visor to the roof the Standard's requirement was exceeded. If a front seat occupant's head contacts that point in a crash, the occupant's injury could be increased. Correction Dealers are to install an energy absorbing device between the front headliner and the vehicle roof. Vehicles Involved Involved are certain 2005-2006 Chevrolet Cobalt Coupe vehicles without roof-mounted side impact airbags and built within the VIN breakpoints shown. IMPORTANT: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through GM DealerWorld Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Inspection Determine if the vehicle is equipped with side impact air bags. Refer to GMVIS to verify vehicle content. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15282 ^ If the vehicle is equipped with side impact air bags, do not perform the service procedure in this bulletin. No further action is required. Submit a claim for Vehicle is Equipped with Side Impact Air Bags, labor operation V 1593 for 0.2. Interim Production Repair Current Production and Service Repair ^ If the vehicle does not have side impact air bags, refer to the service procedure in this bulletin. Perform Steps 1-4 on the driver's side of the vehicle only. After performing Steps 1-4, the headliner will drop about 203 mm (8 in), which will provide adequate room to determine if the energy absorbing (EA) piece has been installed. - If either the interim production or current production/service repair have been performed, reinstall the headliner. A-pillar trim panel, and sunshade. Submit a claim for Inspect Vehicle to Determine if Energy Absorbing Device is Installed, labor operation V 1594 for 0.4. - If the production repair has not been performed, complete the service procedure in this bulletin. Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Submit a claim for Install Energy Absorbing Device, labor operation V 1556 for 0.7. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15283 transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with a an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage, age of vehicle, or ownership, from this time Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15284 forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Tools Required Hot Glue Gun 1. Remove the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. 2. Remove the sunshades from the vehicle. Refer to Sunshade Replacement in SI. 3. Remove the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. 4. Remove the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Important: The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece into the headliner. Use GM Care Hot Melt Adhesive Sticks (P/N 12377914) or equivalent to glue the EA plastic piece into the headliner. 5. Locate the installation anchor points (2) for installing the energy absorbing (EA) plastic piece (3) onto the headliner (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15285 6. Apply hot glue to the energy absorbing (EA) plastic piece. Important: Ensure that the energy absorbing (EA) plastic piece is installed properly. The tail ends of the energy absorbing (EA) plastic piece (2) should wrap around the anchor posts (1) of the headliner material. The body of the EA plastic piece should be firmly attached to the headliner. 7. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue. 8. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades. 9. Install the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. 10. Install the sunshades. Refer to Sunshade Replacement in SI. 11. Install the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. 12. Install the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15286 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15287 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Recalls for Headliner: > NHTSA07V014000 > Jan > 07 > Recall 07V014000: Occupant Impact Non-Compliance Headliner: Recalls Recall 07V014000: Occupant Impact Non-Compliance MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Cobalt 2005-2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 07V014000 MFG'S REPORT DATE: January 16, 2007 COMPONENT: Structure POTENTIAL NUMBER OF UNITS AFFECTED: 98707 SUMMARY: Certain passenger vehicles not equipped with optional roof-mounted side impact air bags fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 201, "Occupant Protection In Interior Impact." CONSEQUENCE: In a crash, head impact protection may be inadequate. REMEDY: Dealers will install energy absorbing plastic to the headliner trim to reduce the severity of head impacts in a crash. The recall is expected to begin during March 2007. Owners may contact Chevrolet at 1-800-630-2438. NOTES: GM recall No. 06217. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection Technical Service Bulletin # 06221A Date: 070413 Campaign - Increase of Head Impact Protection Bulletin No.: 06221A Date: April 13, 2007 CUSTOMER SATISFACTION Subject: 06221A - Modification to Increase Head Impact Protection Models: 2005-2006 Chevrolet Cobalt Coupe 2006 Pontiac Pursuit Coupe Without Roof-Mounted Side Impact Airbags Supercede: THIS BULLETIN IS BEING REVISED TO UPDATE THE SERVICE PROCEDURE AND ADD LABOR OPERATIONS. PLEASE DISCARD CORPORATE BULLETIN 06221, ISSUED MARCH 2007. Condition GM recently improved the head impact protection in certain 2007 model year vehicles. This added protection will reduce the risk of injury if a front seat occupant's head were to impact a point near the attachment of the sun visor to the roof. GM is making similar changes to certain 2005-2006 Chevrolet Cobalt Coupe and 2006 Pontiac Pursuit Coupe vehicles that were built before these changes were implemented. Correction Dealers are to install an energy-absorbing device between the front headliner and the vehicle roof. Vehicles Involved Involved are certain 2005-2006 Chevrolet Cobalt Coupe and 2006 Pontiac Pursuit Coupe vehicles not equipped with optional roof-mounted side impact airbags and built within the VIN breakpoints shown. Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through GMintoNet Recall Reports. Dealers will not have a report available it they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15297 Parts Information Parts required to complete this program are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Inspection Determine if the vehicle is equipped with side impact air bags. Refer to GMVIS to verify vehicle content. If the vehicle is equipped with side impact air bags, do not perform the service procedure in this bulletin. No further action is required. Submit a claim for Vehicle is Equipped with Side Impact Air Bags, labor operation V1595 for 0.2. If the vehicle does not have side impact air bags, refer to the service procedure in this bulletin. Perform Steps 1-4 on the driver's side of the vehicle only. After performing Steps 1-4, the headliner will drop about 203 mm (8 in), which will provide adequate room to determine if the energy absorbing (EA) piece has been installed. If either the interim production or current production/service repair have been performed, re-install the headliner, A-pillar trim panel, and sunshade. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15298 Submit a claim for Inspect Vehicle to Determine if Energy Absorbing Device is Installed, labor operation V1596 for 0.4. If the production repair has not been performed, complete the service procedure in this bulletin. Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Submit a claim for Install Energy Absorbing Device, labor operation V1557 for 0.7. Service Procedure Tools Required Hot Glue Gun Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Remove the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. Remove the sunshades from the vehicle. Refer to Sunshade Replacement in SI. Remove the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. Remove the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece into the headliner. Use hot melt adhesive sticks to glue the EA plastic piece into the headliner. Locate the installation anchor points (2) for installing the energy absorbing (EA) plastic piece (3) onto the headliner (1). Apply hot glue to the energy absorbing (EA) plastic piece. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15299 Ensure that the energy absorbing (EA) plastic piece is installed properly. The tail ends of the energy absorbing (EA) plastic piece (2) should wrap around the anchor posts (1) of the headliner material. The body of the EA plastic piece should be firmly attached to the headliner. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades. Install the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. Install the sunshades. Refer to Sunshade Replacement in SI. Install the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. Install the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15300 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06221A > Apr > 07 > Campaign - Increase of Head Impact Protection > Page 15301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance Technical Service Bulletin # 06217A Date: 070404 Recall - Head Impact Non-Compliance Subject: FMVSS Noncompliance - Head Impact Protection # 06217A - (04/04/2007) Models: 2005-2006 Chevrolet Cobalt Coupe Without Roof-Mounted Side Impact Airbags THIS BULLETIN IS BEING REVISED TO UPDATE THE SERVICE PROCEDURE AND ADD LABOR OPERATIONS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 06217, ISSUED MARCH 2007. Condition General Motors has decided that certain 2005-2006 Chevrolet Cobalt Coupe vehicles not equipped with optional roof-mounted side impact airbags fail to conform to Federal Motor Vehicle Safety Standard 201, "Occupant Protection in Interior Impact". In tests at an impact point near the attachment of the sun visor to the roof the Standard's requirement was exceeded. If a front seat occupant's head contacts that point in a crash, the occupant's injury could be increased. Correction Dealers are to install an energy absorbing device between the front headliner and the vehicle roof. Vehicles Involved Involved are certain 2005-2006 Chevrolet Cobalt Coupe vehicles without roof-mounted side impact airbags and built within the VIN breakpoints shown. IMPORTANT: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through GM DealerWorld Recall Information. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Inspection Determine if the vehicle is equipped with side impact air bags. Refer to GMVIS to verify vehicle content. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15306 ^ If the vehicle is equipped with side impact air bags, do not perform the service procedure in this bulletin. No further action is required. Submit a claim for Vehicle is Equipped with Side Impact Air Bags, labor operation V 1593 for 0.2. Interim Production Repair Current Production and Service Repair ^ If the vehicle does not have side impact air bags, refer to the service procedure in this bulletin. Perform Steps 1-4 on the driver's side of the vehicle only. After performing Steps 1-4, the headliner will drop about 203 mm (8 in), which will provide adequate room to determine if the energy absorbing (EA) piece has been installed. - If either the interim production or current production/service repair have been performed, reinstall the headliner. A-pillar trim panel, and sunshade. Submit a claim for Inspect Vehicle to Determine if Energy Absorbing Device is Installed, labor operation V 1594 for 0.4. - If the production repair has not been performed, complete the service procedure in this bulletin. Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations. Submit a claim for Install Energy Absorbing Device, labor operation V 1556 for 0.7. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15307 transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with a an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers regardless of mileage, age of vehicle, or ownership, from this time Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15308 forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Tools Required Hot Glue Gun 1. Remove the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. 2. Remove the sunshades from the vehicle. Refer to Sunshade Replacement in SI. 3. Remove the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. 4. Remove the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Important: The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece into the headliner. Use GM Care Hot Melt Adhesive Sticks (P/N 12377914) or equivalent to glue the EA plastic piece into the headliner. 5. Locate the installation anchor points (2) for installing the energy absorbing (EA) plastic piece (3) onto the headliner (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15309 6. Apply hot glue to the energy absorbing (EA) plastic piece. Important: Ensure that the energy absorbing (EA) plastic piece is installed properly. The tail ends of the energy absorbing (EA) plastic piece (2) should wrap around the anchor posts (1) of the headliner material. The body of the EA plastic piece should be firmly attached to the headliner. 7. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue. 8. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades. 9. Install the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI. 10. Install the sunshades. Refer to Sunshade Replacement in SI. 11. Install the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI. 12. Install the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15310 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 06217A > Apr > 07 > Recall - Head Impact Non-Compliance > Page 15311 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > NHTSA07V014000 > Jan > 07 > Recall 07V014000: Occupant Impact Non-Compliance Headliner: All Technical Service Bulletins Recall 07V014000: Occupant Impact Non-Compliance MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Cobalt 2005-2006 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 07V014000 MFG'S REPORT DATE: January 16, 2007 COMPONENT: Structure POTENTIAL NUMBER OF UNITS AFFECTED: 98707 SUMMARY: Certain passenger vehicles not equipped with optional roof-mounted side impact air bags fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 201, "Occupant Protection In Interior Impact." CONSEQUENCE: In a crash, head impact protection may be inadequate. REMEDY: Dealers will install energy absorbing plastic to the headliner trim to reduce the severity of head impacts in a crash. The recall is expected to begin during March 2007. Owners may contact Chevrolet at 1-800-630-2438. NOTES: GM recall No. 06217. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 15316 Headliner: Service and Repair Headliner Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement Rear Shelf: Service and Repair Rear Window Panel Rear Reinforcement Replacement Rear Window Panel Rear Reinforcement Replacement Removal Procedure CAUTION: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR. 2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Note the number and location of the factory welds for installation of the rear enforcement to the rear window panel. 6. Locate and drill out all the necessary factory welds. 7. Remove the rear reinforcement to the rear window panel. Installation Procedure IMPORTANT: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15324 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. 4. Position the rear enforcement to the rear window panel. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repaired area. 10. Connect the negative battery cable. 11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15325 Rear Shelf: Service and Repair Rear Window Panel Reinforcement Replacement Rear Window Panel Reinforcement Replacement Removal Procedure CAUTION: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR. 2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Note the number and location of the factory welds for installation of the rear window reinforcement. 6. Locate and drill out all the necessary factory welds. 7. Remove the rear window reinforcement. Installation Procedure IMPORTANT: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15326 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. 4. Position the rear window reinforcement and clamp in place. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repaired area. 10. Connect the negative battery cable. 11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15327 Rear Shelf: Service and Repair Rear Window Panel Replacement Rear Window Panel Replacement Removal Procedure CAUTION: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR. 2. Disconnect the negative battery cable 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. IMPORTANT: Note the number and location of the factory welds for installation of the rear window panel. 6. Locate and drill out all the necessary factory welds. 7. Remove the rear window panel. Installation Procedure IMPORTANT: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15328 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. 4. Position the rear window panel. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair. 9. Paint the repaired area. 10. Connect the negative battery cable 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Rear Window Panel Rear Reinforcement Replacement > Page 15329 Rear Shelf: Service and Repair Trim Panel Replacement - Rear Window Shelf Trim Panel Replacement - Rear Window Shelf Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair Scuff Plate: Service and Repair Compartment Sill Plate Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures Sun Visor: Procedures Sunshade Replacement SUNSHADE REPLACEMENT Sunshade Retainer Bezel Replacement SUNSHADE RETAINER BEZEL REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 15337 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 15338 Sun Visor: Removal and Replacement Sunshade Replacement Sunshade Replacement Sunshade Retainer Bezel Replacement Sunshade Retainer Bezel Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 15339 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear Trim Panel: Service and Repair Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15344 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Lower Garnish Molding Replacement - Center Pillar Lower Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15345 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Upper Garnish Molding Replacement - Center Pillar Upper Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15346 Trim Panel: Service and Repair Garnish Molding Replacement - Lock Pillar Lower Garnish Molding Replacement - Lock Pillar Lower Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15347 Trim Panel: Service and Repair Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Garnish Molding Replacement - Center Pillar Lower Garnish Molding Replacement - Center Pillar Lower Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15348 Garnish Molding Replacement - Center Pillar Upper Garnish Molding Replacement - Center Pillar Upper Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15349 Garnish Molding Replacement - Lock Pillar Lower Garnish Molding Replacement - Lock Pillar Lower Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15350 Garnish Molding Replacement - Lock Pillar Upper Garnish Molding Replacement - Lock Pillar Upper Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15351 Instrument Panel Trim Panel Replacement The contents of this article reflects the changes identified in TSB 05_08_49_029 Bulletin No. 05-08-49-029 Date: December 09, 2005 SERVICE MANUAL UPDATE Subject: Revised Trim Panel Replacement - Instrument Panel (I/P) Center Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Trim Panel Replacement - Instrument Panel(I/P)Center Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15352 Trim Panel Replacement - Rear Window Shelf Trim Panel Replacement - Rear Window Shelf Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15353 Windshield Garnish Molding Replacement Windshield Garnish Molding Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 15354 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Door / Cover > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage Compartment Door / Cover: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. Utility Storage Compartment Door / Cover: Customer Interest Interior - Instrument Panel Compartment Bin Inop. TECHNICAL Bulletin No.: 09-08-49-018 Date: November 20, 2009 Subject: Instrument Panel (I/P) Outer Compartment Bin is Inoperative or Loose (Replace Steering Column Opening Filler Panel) Models: 2005-2010 Chevrolet Cobalt 2007-2009 Pontiac G5 2010 Pontiac G5 (Canada Only) Condition Some customers may comment that the instrument panel (I/P) outer compartment bin (1) is inoperative or loose. Cause This condition may be caused by the outboard pivot (1) on the steering column opening filler panel breaking and not properly holding the compartment bin in place. Correction Replace the steering column opening filler panel and transfer the compartment bin and necessary components to the new panel. Refer to Steering Column Opening Filler Replacement in SI. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Door / Cover > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage Compartment Door / Cover: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. > Page 15364 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Door / Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility Storage Compartment Door / Cover: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. Utility Storage Compartment Door / Cover: All Technical Service Bulletins Interior - Instrument Panel Compartment Bin Inop. TECHNICAL Bulletin No.: 09-08-49-018 Date: November 20, 2009 Subject: Instrument Panel (I/P) Outer Compartment Bin is Inoperative or Loose (Replace Steering Column Opening Filler Panel) Models: 2005-2010 Chevrolet Cobalt 2007-2009 Pontiac G5 2010 Pontiac G5 (Canada Only) Condition Some customers may comment that the instrument panel (I/P) outer compartment bin (1) is inoperative or loose. Cause This condition may be caused by the outboard pivot (1) on the steering column opening filler panel breaking and not properly holding the compartment bin in place. Correction Replace the steering column opening filler panel and transfer the compartment bin and necessary components to the new panel. Refer to Steering Column Opening Filler Replacement in SI. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Door / Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility Storage Compartment Door / Cover: > 09-08-49-018 > Nov > 09 > Interior - Instrument Panel Compartment Bin Inop. > Page 15370 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Lock Cylinder Replacement - Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Page 15376 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15381 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15382 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15383 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Locks - Remote Control Door Lock Receiver Replacement Keyless Entry Receiver: Technical Service Bulletins Locks - Remote Control Door Lock Receiver Replacement Bulletin No.: 05-08-52-003 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Remote Control Door Lock Receiver Replacement Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Remote Control Door Lock Receiver Replacement procedure in the Doors sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Locks - Remote Control Door Lock Receiver Replacement > Page 15389 The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 15390 Remote Control Door Lock Receiver (RCDLR) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 15391 Keyless Entry Receiver: Service and Repair The content of this article/image reflects the changes identified in TSB- 05-08-52-003 Dated: October 21, 2005 Remote Control Door Lock Reciever Replavement Components Procedure REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Technical Service Bulletins > Page 15392 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics Keyless Starting System: Technical Service Bulletins Remote Starting System - System Inoperative Diagnostics INFORMATION Bulletin No.: 08-08-52-002 Date: February 27, 2008 Subject: Diagnostic Information for Inoperative Remote Vehicle Start Models: 2005-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2008 HUMMER H2 with Remote Keyless Entry RPOs AP3 or AP8 Remote Vehicle Start (RVS) Inoperative Diagnostic Concerns Information on Hood Latch Switches One of the many components involved in the Remote Vehicle Starting System is the Hood Latch Switch. The state of this switch is checked by the BCM during a remote vehicle start request and the component must function properly in order for the vehicle to commence a remote start event. During the infancy of this option (RPO AP3/AP8) parts return analysis showed a significantly shorter than expected component life for the Hood Latch Switch shared across many different GM vehicles. The switches currently being factory installed, and sent as service replacement parts, are vastly improved in design and suitably robust. Most hood latch switches currently returned under warranty are analyzed and determined to have no trouble found (NTF). It is understandable and desirable that technicians gain familiarity with the vehicles they service on a daily basis, however it is required that technicians follow Strategy Based Diagnostics before replacing this switch. Important: The ONLY way to repair or replace a hood latch switch is to replace the LATCH ASSEMBLY. The switch CANNOT be serviced separately from the latch and is NOT AVAILABLE from GMSPO. Any effort to remove the switch from the latch will permanently damage the switch and void the warranty coverage of that part. Important: The hood switch provides status of the hood to the BCM for RVS purposes. The switch is integrated into the hood latch assembly. The hood ajar switch provides two separate inputs to the BCM. These separate inputs allow the BCM to actively monitor for a hood ajar switch fault. RVS System Operation The remote vehicle start (RVS) function allows engine starting while not in the vehicle. It also allows the vehicle HVAC system and other vehicle systems to enable providing a comfortable vehicle upon entry. RVS functions have an operating range of up to 59 m (195 ft) depending on conditions. The RVS sequence begins by pressing and releasing the lock button and then pressing and holding the RVS buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate the vehicle has received the remote start request. Each time an RVS is performed the vehicle doors are locked; however they may then be unlocked/locked with the transmitter or vehicle key at any time. Once activated the engine is allowed to run for 10 minutes. The RVS time may be extended by an additional 10 minutes by again pressing and releasing the lock button and then pressing and holding the RVS buttons on the transmitter. This feature is called an RVS continue and allows a maximum of 20 minutes of engine running. If the RVS continue is performed at 7 minutes into the initial 10 minute time-out a total of 17 minutes of engine running would occur. The RVS event may be suspended at any time by pressing only the RVS button on the transmitter or by entering the vehicle and turning ON the hazard lamps. RVS System Description Remote vehicle start (RVS) begins as a Radio Frequency (RF) message received by the remote control door lock receiver (RCDLR) from a keyless entry transmitter. The RVS request is sent by the RCDLR to the body control module (BCM) via serial data line. The BCM monitors system conditions such as content theft deterrent (CTD) closures ajar status and body DTCs to determine if an RVS event will occur. If conditions are determined to be acceptable the RVS message is sent to the engine control module (ECM). The ECM monitors system conditions such as engine control parameters and vehicle theft deterrent (VTD) to determine if engine starting will be allowed. If conditions are acceptable the ECM will initiate engine starting. During Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Remote Starting System - System Inoperative Diagnostics > Page 15397 the engine run time in an RVS attempt before the operator enters the vehicle the ECM may discontinue engine operation if system conditions require it or a message is received from the BCM requesting the engine be turned OFF. Reasons an RVS event will NOT Happen The RVS System WILL NOT operate if any of the following conditions are present: ^ A current vehicle DTC that illuminates the malfunction indicator lamp (MIL) is set - obtain vehicle DTCs. ^ Keyless Entry Transmitter is not Operational. ^ The vehicle is in Valet Mode. ^ RVS is Disabled through Vehicle Personalization. ^ More than 2 Remote Starts have been attempted. ^ The HAZARD switch is in the ON position. ^ A current HAZARD switch DTC is set. ^ A current HOOD AJAR DTC is set. ^ Rear compartment lid is ajar. ^ Any Door is not locked. ^ The Content Theft Deterrent (CTD) system detects an alarm trigger. ^ Engine RPM greater than 0 Detected. ^ Excessive Coolant TEMP is registered. ^ Accelerator pedal position greater than 0 percent. ^ Vehicle is not in PARK. ^ A current Vehicle Theft Deterrent Malfunction DTC. ^ A current Automatic Transmission Shift Lock Control System DTC is set. ^ A vehicle speed sensor signal is detected by the ECM. ^ Vehicle power mode is incorrect. Diagnostic Information Starting Point For additional assistance refer to Remote Vehicle Start Inoperative in the Electronic Service Information. This section will guide you through the complete Strategy Based Diagnostics and provide Specific Diagnostic Procedure Instructions. Warranty Information Please refer to the published Labor Time Guides and claim the corresponding labor operation for the component(s) replaced. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a flat object, with a thin edge, into the notch located below the remote alarm button and separate the bottom half from the top half of the transmitter. NOTE: When replacing the battery, use care not to touch any of the circuitry. Static from your body transferred to these surfaces may damage the transmitter. 2. Remove the battery from the transmitter. INSTALLATION PROCEDURE 1. Install the battery into the transmitter with the positive side of the battery facing up. 2. Snap the front and back half of the transmitter together. 3. Ensure the transmitter halves are tight to prevent moisture from intruding into the transmitter. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15406 Door Lock Switch - Passenger (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15407 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Rear Compartment Lid Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation Memory Positioning Systems: Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION PERSONALIZATION The following options can be accessed in order by pressing the MENU button anytime while the vehicle is in ON. Pressing the INFO and RESET/SELECT buttons at the same time provides the MENU switch function. Press the MENU button to scroll through each option. All of the personalization options may not be available on your vehicle. Only the options available will be displayed on your driver information center (DIC). Oil Life Monitor Reset - Units Selection (English/Metric) - Remote Start Capability - Horn Chirp During Remote Keyless Entry Locking - Horn Chirp During Remote Keyless Entry Unlocking - Exterior Light Flash During Remote Keyless Entry Locking or Unlocking - Delayed Locking - Automatic Vehicle Unlocking: Specific Doors - Automatic Vehicle Unlocking: When Key is Off or When Shift To Park - Exterior Perimeter Lighting During Remote Keyless Entry Unlock - Security System Passive or Remote Keyless Entry Arming - Select Language: (English, French, Spanish or German) When the desired option is reached, use the ENTER button to toggle between the modes of that option. To make a selection, press the MENU button again. If no selection is made within 10 seconds, the display will revert back to the previous information displayed. The MENU mode is exited when the INFO button is pressed, a 10 second time period has elapsed, the ignition is turned to OFF, or the end of the MENU list is reached. The following display messages may appear on your vehicles driver information center (DIC) by pressing the MENU button: Oil Life Reset: When this option is displayed you can reset the Oil Life Monitor system. To reset the system to 100 percent, press and hold the ENTER button for at least 1 second. An ACKNOWLEDGED display message will appear for 3 seconds or until the next button is pressed. This will tell you the system has been reset. Units: When UNITS appears on the display, press the ENTER button to move between Metric or English. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is English. If you choose English, all information will be displayed in English units. For example, distance in miles and fuel economy in miles per gallon is displayed. If you choose metric, all information will be displayed in metric units. For example, distance in kilometers and fuel economy in liters per 100 kilometers is displayed. The unit measurement will also change the trip odometer, temperature, and average fuel economy displays. Remote Start: The remote start feature, if equipped, can be enabled or disabled. When REMOTE START appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Lock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the LOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Unlock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When UNLOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is OFF. Light Flash: If your vehicle has remote keyless entry, this feature which allows the vehicle exterior perimeter lighting to flash every time the LOCK or UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LIGHT FLASH appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Delay Lock: The delayed locking feature, which delays the actual locking of the vehicle, can be enabled or disabled. When DELAY LOCK appears Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Page 15419 on the display, use the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Auto Unlk The automatic door unlocking feature, which allows the vehicle to automatically unlock certain doors, can be enabled or disabled. When AUTO UNLK appears on the display, use the ENTER button to move between: ALL, DRVR, or NONE. When you have made your choice, press and the MENU button to record your selection. The initial setting from the factory is ALL. Unlk: This feature determines when the automatic door unlocking will occur, when either the key is turned to OFF or the vehicle is shifted into PARK (P). When UNLK appears on the display, use the ENTER button to move between KEY OFF and SHIFT TO P. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is SHIFT TO P. EXT Lights: If your vehicle has remote keyless entry, this feature, which allows the vehicle exterior perimeter lighting to turn ON each time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When EXT LIGHTS appears on the display, use the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Security: If your vehicle has the remote keyless entry system, this feature allows you to select the method used to arm the vehicle security system. When SECURITY appears on the display, use the ENTER button to move between RKE and PASSIVE. When you have made your choice, press the MENU button to record your selection. See Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information. Language: To select your choice of language, use the ENTER button to move between the optional languages. The languages are English, French, German and Spanish. Choosing a language will display all of the information on the DIC in the desired language. When you have made your choice, press the MENU button for at least one second to record your selection. The initial setting from the factory is ENGLISH. Enter: The ENTER button is used to reset certain functions and turn OFF or acknowledge messages on the DIC display. The ENTER button also toggles through the options available in each personalization menu. RADIO PRESET WITH REMOTE KEYLESS ENTRY The vehicle may be equipped with a radio personalization feature. This feature allows you to store radio preset stations to the remote keyless entry transmitter used to unlock the doors. Two drivers can store different preset stations and the radio recalls the stored radio settings associated with a particular transmitter. When UNLOCK is pressed on the remote, the preset stations that the driver stored is recalled. Refer to Radio/Audio System Description and Operation in Radio, Stereo, and Compact Disc for more information about the radio. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative Mirror Adjustment Cable: Customer Interest Body - L/H or R/H Manual Mirror Control Inoperative Bulletin No.: 05-08-64-035 Date: October 28, 2005 TECHNICAL Subject: Left or Right Manual Mirror Control Inoperative (Replace Plastic Control Tower) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside manual mirror control is inoperative. Cause This condition may be caused by a damaged plastic control tower which is unable to hold the adjustment in place. Correction Replace the plastic control tower following the procedure below: 1. Remove the upper door trim. 2. Remove the 3 nuts that retain the mirror to the door. 3. Remove the mirror. 4. Remove the plastic control tower from the cable by releasing the tab and pulling. Refer to the illustration above. 5. Install the plastic control tower onto the cable. 6. Install the mirror to the door. 7. Install the 3 nuts that retain the mirror to the door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative > Page 15428 Tighten Tighten the 3 nuts to 10 N.m (89 lb in). 8. Install the upper door trim. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative Mirror Adjustment Cable: All Technical Service Bulletins Body - L/H or R/H Manual Mirror Control Inoperative Bulletin No.: 05-08-64-035 Date: October 28, 2005 TECHNICAL Subject: Left or Right Manual Mirror Control Inoperative (Replace Plastic Control Tower) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside manual mirror control is inoperative. Cause This condition may be caused by a damaged plastic control tower which is unable to hold the adjustment in place. Correction Replace the plastic control tower following the procedure below: 1. Remove the upper door trim. 2. Remove the 3 nuts that retain the mirror to the door. 3. Remove the mirror. 4. Remove the plastic control tower from the cable by releasing the tab and pulling. Refer to the illustration above. 5. Install the plastic control tower onto the cable. 6. Install the mirror to the door. 7. Install the 3 nuts that retain the mirror to the door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative > Page 15434 Tighten Tighten the 3 nuts to 10 N.m (89 lb in). 8. Install the upper door trim. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mirror Adjustment Cable: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever Shifter M/T: All Technical Service Bulletins M/T - Shifter Knob Loose/Detached From Shift Lever Bulletin No.: 05-07-29-006A Date: February 13, 2006 TECHNICAL Subject: Shifter Knob Loose or Detached From Shift Control Lever (Secure Shifter Knob with Adhesive and Fastener) Models: 2005 Chevrolet Cobalt SS Supercharged 2004-2005 Saturn ION Red Line with 5-Speed Manual Transaxle (RPO MU3) Supercede: This bulletin is being revised to delete the WPC form. Parts are now available from GMSPO and Saturn SPO. Please discard Corporate Bulletin Number 05-07-29-006 (Section 07 Transmission/Transaxle). Condition Some customers may comment that the shift control knob (shifter knob) may be loose or detached from the shift control lever. Cause The interference fit between the shift control knob and the shift control lever may allow the shift control knob to become loose or detached. Correction Secure the original equipment or new service shift control knob to the shift control lever using adhesive and a self-tapping fastener. Service Procedure Important: Make sure the leather boot is still in place around the shift control lever base in order to prevent drilling debris from falling into the shifter mechanism. Important: Re-use the original equipment shifter knob whenever possible. Only use a new service shifter knob if the original equipment knob is damaged or missing. 1. Carefully remove the emblem from the original equipment shift control knob. Save this emblem for re-use if retaining the original equipment shift control knob or for re-use on the new service shift control knob, if applicable. Important: The service shifter knob may feel slightly "looser" than the production part. This is a normal characteristic. Do NOT replace the entire shift control assembly for this condition. 2. Place the shift control knob back on the shift control lever. Ensure that the shifter knob is correctly oriented. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mirror Adjustment Cable: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 15440 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mirror Adjustment Cable: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 15441 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mirror Adjustment Cable: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 15447 3. Cut the three plastic legs on the shift control knob face and remove the central plastic area. 4. Locate the center of the shift knob face and mark with center punch. 5. Drill a 4.76 mm (0.1875 in [3/16 in]) hole through the shift control knob face and into the shift control lever to a depth of 14.5 mm (0.57 in). Diameter 4.76 mm (0.1875 in [3/16 in]) Depth 14.5 mm (0.57 in) 6. Countersink chamfer of hole to allow the fastener to be flush with the shift control knob face. Use a 8.73 mm (0.344 in [11/32 in]) drill bit to countersink. Top diameter 10.4 mm (0.41 in) 7. Remove the shift control knob from the shift control lever. Note: Do not allow any adhesive to drip or run lower than the top 5 mm (0.2 in) of the shift control lever shaft. If the adhesive comes into contact with the reverse lockout mechanism, the reverse lockout may be rendered inoperative. Important: Use *Loctite(R) Accelerant 7471 or 7649 primer and *Loctite(R) Threadlocker 270(TM) thread locking adhesive. 8. Apply accelerant to the top 5 mm (0.2 in) of the shift control lever shaft first - then apply adhesive to this area. Keep a clean dry shop cloth readily available to prevent any drips or runs. 9. Seat the shift control knob over the shift control lever. Ensure that the spring and the foam rings are correctly seated. Ensure that the shift control Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mirror Adjustment Cable: > 05-07-29-006A > Feb > 06 > M/T - Shifter Knob Loose/Detached From Shift Lever > Page 15448 knob is correctly oriented. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Place a M5x12 self-tapping screw into the hole and tighten the screw until the fastener head is flush. Tighten Tighten the fastener to 5.68 N.m (50 lb in). Important: Do not operate the lever until the adhesive has dried (at least 30 minutes). 11. Position and fit the emblem over the shift control knob. 12. Vacuum and clean any debris. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative Mirror Adjustment Handle: Customer Interest Body - L/H or R/H Manual Mirror Control Inoperative Bulletin No.: 05-08-64-035 Date: October 28, 2005 TECHNICAL Subject: Left or Right Manual Mirror Control Inoperative (Replace Plastic Control Tower) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside manual mirror control is inoperative. Cause This condition may be caused by a damaged plastic control tower which is unable to hold the adjustment in place. Correction Replace the plastic control tower following the procedure below: 1. Remove the upper door trim. 2. Remove the 3 nuts that retain the mirror to the door. 3. Remove the mirror. 4. Remove the plastic control tower from the cable by releasing the tab and pulling. Refer to the illustration above. 5. Install the plastic control tower onto the cable. 6. Install the mirror to the door. 7. Install the 3 nuts that retain the mirror to the door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative > Page 15457 Tighten Tighten the 3 nuts to 10 N.m (89 lb in). 8. Install the upper door trim. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative Mirror Adjustment Handle: All Technical Service Bulletins Body - L/H or R/H Manual Mirror Control Inoperative Bulletin No.: 05-08-64-035 Date: October 28, 2005 TECHNICAL Subject: Left or Right Manual Mirror Control Inoperative (Replace Plastic Control Tower) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the outside manual mirror control is inoperative. Cause This condition may be caused by a damaged plastic control tower which is unable to hold the adjustment in place. Correction Replace the plastic control tower following the procedure below: 1. Remove the upper door trim. 2. Remove the 3 nuts that retain the mirror to the door. 3. Remove the mirror. 4. Remove the plastic control tower from the cable by releasing the tab and pulling. Refer to the illustration above. 5. Install the plastic control tower onto the cable. 6. Install the mirror to the door. 7. Install the 3 nuts that retain the mirror to the door. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 05-08-64-035 > Oct > 05 > Body - L/H or R/H Manual Mirror Control Inoperative > Page 15463 Tighten Tighten the 3 nuts to 10 N.m (89 lb in). 8. Install the upper door trim. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Outside Rearview Mirror Switch (With RPO Code DG7) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 15469 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15479 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15485 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 15495 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 15496 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15497 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15498 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15499 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15500 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 15503 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15506 WA130B/46 - WA214M/26 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15507 WA214M/26 - WA215M/38 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15508 WA215M/38 - WA228M/64 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15509 WA228M/64 - WA379E/86 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15510 WA379E/86 - WA397E/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15511 WA397E/25 - WA519F/12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15512 WA526F/72 - WA5456/43 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15513 WA5456/43 - WA703J/22 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15514 WA703J/22 - WA722J/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15515 WA722J/25 - WA722J/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15516 WA800J/98 - WA805K/62 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15517 WA805K/62 - WA811K/87 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15518 WA811K/87 - WA812K/88 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15519 WA812K/88 - WA815K/91 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15520 WA816K/92 - WA817K/63 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15521 WA817K/63 - WA817K/63 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15522 WA817K/63 - WA8265/61 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15523 WA8265/61 - WA8554/40 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15524 WA8554/40 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15525 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15526 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15527 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15528 WA8555/41 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15529 WA8624/50 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15530 WA8624/50 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15531 WA8624/50 - WA9088/94 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15532 WA9088/94 - WA913L/56 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15533 WA913L/56 - WA9260/74 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15534 WA9260/74 - WA9260/74 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15535 WA9260/74 - WA926L/59 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15536 WA926L/59 - WA928L/46 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15537 WA928L/46 - WA929L/15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15538 WA929L/15 - WA929L/15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15539 WA929L/15 - WA930L/68 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15540 WA930L/68 - WA937L/34 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15541 WA9414/34 - WA9539/47 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15542 WA9539/47 - WA9792/39 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15543 WA9792/39 - WA994L/67 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15544 WA994L/67 - WA994L/67 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15545 WA994L/67 - WA994L/67 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15546 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15547 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15548 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located in the rear compartment under the spare tire cover. The label is used to help identify the vehicle original parts and options. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15549 Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15550 WA130B/46 - WA214M/26 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15551 WA214M/26 - WA215M/38 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15552 WA215M/38 - WA228M/64 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15553 WA228M/64 - WA379E/86 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15554 WA379E/86 - WA397E/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15555 WA397E/25 - WA519F/12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15556 WA526F/72 - WA5456/43 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15557 WA5456/43 - WA703J/22 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15558 WA703J/22 - WA722J/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15559 WA722J/25 - WA722J/25 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15560 WA800J/98 - WA805K/62 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15561 WA805K/62 - WA811K/87 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15562 WA811K/87 - WA812K/88 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15563 WA812K/88 - WA815K/91 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15564 WA816K/92 - WA817K/63 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15565 WA817K/63 - WA817K/63 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15566 WA817K/63 - WA8265/61 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15567 WA8265/61 - WA8554/40 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15568 WA8554/40 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15569 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15570 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15571 WA8555/41 - WA8555/41 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15572 WA8555/41 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15573 WA8624/50 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15574 WA8624/50 - WA8624/50 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15575 WA8624/50 - WA9088/94 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15576 WA9088/94 - WA913L/56 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15577 WA913L/56 - WA9260/74 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15578 WA9260/74 - WA9260/74 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15579 WA9260/74 - WA926L/59 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15580 WA926L/59 - WA928L/46 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15581 WA928L/46 - WA929L/15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15582 WA929L/15 - WA929L/15 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15583 WA929L/15 - WA930L/68 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15584 WA930L/68 - WA937L/34 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15585 WA9414/34 - WA9539/47 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15586 WA9539/47 - WA9792/39 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15587 WA9792/39 - WA994L/67 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15588 WA994L/67 - WA994L/67 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15589 WA994L/67 - WA994L/67 Paint Identification Precautions Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15590 PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Parts ID Label Location The vehicle service parts identification label is located in the rear compartment under the spare tire cover. The label is used to help identify the vehicle original parts and options. Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement Seat Heater Control Module: Technical Service Bulletins Interior - Revised Seat Heater Module Replacement Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Front Heated Seat Control Module Replacement procedure in the Seats sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement > Page 15596 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15597 Seat Heater Control Module: Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15598 Passenger Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15599 Seat Heater Control Module: Diagrams Heated Seat Module - Driver (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15600 Heated Seat Module - Passenger (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures The content of this article/image reflects the changes identified in TSB 05-08-50-011 Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 15603 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 15604 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-03-09-005E > Feb > 11 > Suspension Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: Customer Interest Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: All Technical Service Bulletins Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Module: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Module: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 15623 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Module: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 15624 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Module: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 15630 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Module: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 15631 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 15632 Sunroof Control Module (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair SUNROOF SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Cycle the sunroof window to the partially open position. 2. Pull downward on the sunshade. Cycle the sunroof to full open position. Disengage the sunshade from the sunroof glass panel. 3. Depress the panel to one side of the track assembly (1). 4. With a flat-bladed tool, release the front retention clip (3), one of 2 clips located on each side of the sunshade panel. 5. Carefully arch the sunshade upward at the forward center edge. 6. Carefully lift the front edge of the sunshade (4) upward out of the opening. 7. With the sunshade panel depressed to one side of the track, release the rear retention clip. 8. Slightly rotate the sunshade panel in order to remove the panel from the track assembly. 9. Carefully remove the sunshade panel upward from the sunroof module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Page 15638 INSTALLATION PROCEDURE 1. Position rear edge of the sunshade panel to the track assembly. 2. Ensure the retention clip at the rear is positioned into the track assembly. 3. Depress the rear retention clip on the opposite side of the sunshade panel and locate the clip into the track assembly. 4. Release the retention clip. 5. Locate the front edge of the sunshade panel retention clip (2) into the track assembly (1). 6. Arch the forward edge of the sunshade in order to locate the retention clip into the sunshade track. 7. Depress the retention clip on the opposite side. 8. Locate the clip into the track assembly and release. 9. Slide the sunshade panel forward and rearward to ensure free operation is present. 10. With the sunshade partially open, pull downward on the sunshade. Cycle the sunroof to the vent position, allowing the glass panel to travel past the sunshade front edge. 11. Release the sunshade. Cycle the sunroof to the open position. Inspect for proper engagement of the sunroof glass panel and the sunshade panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Headliner Components (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 15642 Sunroof Motor (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor Synchronization Sunroof / Moonroof Motor: Service and Repair Sunroof Motor Synchronization Sunroof Motor Synchronization Synchronization Procedure Important: Verify that both the sunroof motor/actuator and the sunroof guide mechanisms are in the vent position before you begin the synchronization procedure. 1. Plug the motor/actuator into the harness and provide power until the motor/actuator stops in the vent position. If the motor does not operate when powered, then the motor is already in the vent position. 2. If the sunroof window is in the closed position, remove the sunroof window. Refer to Sunroof Window Replacement. 3. Verify that the sunroof guide mechanisms are fully forward and in the vent position. 4. Install the sunroof motor/actuator. 5. Install the sunroof window, if necessary. 6. Operate the sunroof to verify proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor Synchronization > Page 15645 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement SUNROOF MOTOR/ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Disconnect the motor/actuator harness from the sunroof module. IMPORTANT: If the sunroof window is partially closed, remove the actuator first before moving the sunroof window forward. 3. Disconnect the electrical connector from the sunroof motor/actuator. 4. Remove the sunroof motor/actuator bolts (2) from the sunroof module. 5. Remove the sunroof actuator (1) from the sunroof module. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor Synchronization > Page 15646 1. Synchronize the sunroof motor/actuator. Refer to Sunroof Motor Synchronization. 2. Install the sunroof motor/actuator to the sunroof module. 3. Install the sunroof motor/actuator bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 5 N.m (50 lb in). 4. Connect the electrical connector to the sunroof motor/actuator. 5. Secure the electrical harness to the sunroof module. 6. Verify the sunroof operation. 7. Install the headliner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: Customer Interest Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 15655 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: All Technical Service Bulletins Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 15661 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 15662 Headliner Components (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 15663 Sunroof Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. INSTALLATION PROCEDURE 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 15666 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. Installation Procedure 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area Sunroof / Moonroof Track: Customer Interest Body - Rattling Noise From The Sunroof Area TECHNICAL Bulletin No.: 09-08-67-001 Date: January 06, 2009 Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape) Models: 2006-2009 Buick Lucerne 2003-2007 Cadillac CTS 2005-2009 Cadillac STS 2006-2009 Cadillac DTS 2005-2009 Chevrolet Cobalt, Equinox 2006-2009 Chevrolet HHR 2006-2009 Pontiac Torrent 2007-2009 Pontiac G5 2004-2007 Saturn VUE Condition Some customers may comment of a rattling noise coming from the sunroof or roof area. Cause This condition may be caused by the inboard tox rivets, which retain the sunroof center support beam to the side rails, pulling through the side rail track on one or both sides. This may cause the support beam to rattle against the side rail track. Correction Important: Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition is noted. Install flocking tape between the sunroof center support beam and the side rail track. 1. Following SI, lower the front portion of the headliner enough to gain access to the sunroof module center support beam through the opening in the headliner. 2. Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1) between the center support and the side rail track. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area > Page 15675 3. Look for separation of the center support beam and the side rail track. 4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent, approximately 152 mm (6 in) in length. 5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to separate the center support beam and the side rail track. 6. Ensure that the flocking tape is positioned underneath the complete width of the center support beam. 7. Reinstall the headliner. Parts Information Warranty Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area Sunroof / Moonroof Track: All Technical Service Bulletins Body - Rattling Noise From The Sunroof Area TECHNICAL Bulletin No.: 09-08-67-001 Date: January 06, 2009 Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape) Models: 2006-2009 Buick Lucerne 2003-2007 Cadillac CTS 2005-2009 Cadillac STS 2006-2009 Cadillac DTS 2005-2009 Chevrolet Cobalt, Equinox 2006-2009 Chevrolet HHR 2006-2009 Pontiac Torrent 2007-2009 Pontiac G5 2004-2007 Saturn VUE Condition Some customers may comment of a rattling noise coming from the sunroof or roof area. Cause This condition may be caused by the inboard tox rivets, which retain the sunroof center support beam to the side rails, pulling through the side rail track on one or both sides. This may cause the support beam to rattle against the side rail track. Correction Important: Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition is noted. Install flocking tape between the sunroof center support beam and the side rail track. 1. Following SI, lower the front portion of the headliner enough to gain access to the sunroof module center support beam through the opening in the headliner. 2. Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1) between the center support and the side rail track. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area > Page 15681 3. Look for separation of the center support beam and the side rail track. 4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent, approximately 152 mm (6 in) in length. 5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to separate the center support beam and the side rail track. 6. Ensure that the flocking tape is positioned underneath the complete width of the center support beam. 7. Reinstall the headliner. Parts Information Warranty Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 15687 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 15693 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Inspection and Cleaning Drain Hose Routing A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. Check to ensure the front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. Make sure the hoses are not kinked. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Front. 2. Check to ensure the rear drain hoses are routed through the rear pillars and out of the rocker panel. Make sure the rear hoses are properly routed in the metal roof slot and taped in place. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Rear. Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Caution: Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Drain Hose Routing. 6. Remove any hoses that remain plugged. 7. Remove the blockage. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. 8. Reinstall the hose. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headliner Replacement in Interior Trim. 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15698 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Drain Hose Replacement - Front Sunroof Drain Hose Replacement - Front Removal Procedure 1. Remove the headliner. 2. Remove the front drain hose from the sunroof module. 3. Disengage the sunroof drain hose from the attachment points on the windshield pillar. 4. Remove the carpet retainer. 5. Pull back the front lower insulator. 6. Remove the hinge pillar inner insulators to gain access to the front drain hose routing area inside the hinge pillar below the I/P. 7. Pull the front drain hose out of the front lower hinge pillar. 8. Tie a 3-foot length of string onto the lower end of the front drain hose. 9. Remove the hose through the top of the I/P. Do NOT pull the string all of the way out. 10. Disconnect the string from the hose. Installation Procedure 1. Attach the string used in the removal procedure to the lower end of the drain hose. 2. Pulling the hose in place with the string, route the front drain hose down the windshield post and into the front lower hinge pillar. 3. Push the drain hose into the hole in the front lower hinge pillar. Insert approximately 25 mm (1 in) of drain hose into the hole. 4. Connect the drain hose to the sunroof module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15699 5. Connect the front drain hose to the attachments on the windshield pillar. 6. Install the hinge pillar lower insulators. 7. Install the front lower insulator. 8. Install the carpet retainer. 9. Install the headliner. Sunroof Drain Hose Replacement - Rear Sunroof Drain Hose Replacement - Rear Removal Procedure 1. Remove the headliner. 2. Remove the rear drain hose from the sunroof module. 3. Disengage the sunroof drain hose from the attachment points on the rear window pillar. 4. Remove the rear compartment trim panel. 5. Pull the sunroof drain hose and grommet out of the rear compartment panel. 6. Pull the rear drain hose out of the rear compartment. Remove the rear drain hose. Installation Procedure 1. Route the rear drain hose down the rear window pillar. 2. Connect the rear drain hose to the sunroof module. 3. Connect the rear drain hose to the attachments on the rear window pillar. 4. Push the rear drain hose and grommet into the hole in the rear compartment panel until the grommet is fully engaged. 5. Install the rear compartment trim panel. 6. Install the headliner. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: Customer Interest Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 06-03-09-005E > Feb > 11 > Suspension - Rear End Squawk Noise On Low Speed Bumps Sunroof / Moonroof Module: All Technical Service Bulletins Suspension - Rear End Squawk Noise On Low Speed Bumps TECHNICAL Bulletin No.: 06-03-09-005E Date: February 07, 2011 Subject: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) Models: 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 06-03-09-005D (Section 03 - Suspension). Condition Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds. Cause The cause of this noise may be the rear suspension insulators. Correction Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 15713 Sunroof Control Module (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the adjusting screws. 4. Adjust the corners of the glass panel (3) using the following guidelines: * Adjust the front of the sunroof window (2) flush to 1 mm (0.04 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window (1) flush to 1 mm (0.04 in) above the top surface of the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the sunroof window adjustment screws. Tighten the sunroof window adjusting screws to 4 N.m (35 lb in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 15717 Sunroof / Moonroof Panel: Service and Repair SUNROOF WINDOW REPLACEMENT REMOVAL PROCEDURE 1. Cycle the sunroof window to the vent position. NOTE: In order to prevent damage to the paint, mask the roof panel in front of the sunroof opening using masking tape and paper. 2. Slide the sunshade rearward. 3. Remove the sunroof window screws (1) from the window. IMPORTANT: Do NOT scratch the roof surface or the sunroof window. 4. Lift the sunroof window from the sunroof opening. INSTALLATION PROCEDURE 1. Position the sunroof window into the opening. 2. Ensure that the window trade mark points rearward. 3. Install the sunroof window screws (1) to the window. Do not tighten the screws. 4. Carefully close the sunroof window from the vent position to the full closed position. 5. Adjust the sunroof window. Refer to Sunroof Window Height and Opening Fit Adjustment. 6. Close the sunshade. 7. Cycle the sunroof window to ensure proper operation and fit. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures Head Rest: Procedures Head Restraint Replacement - Front Seat HEAD RESTRAINT REPLACEMENT - FRONT SEAT Head Restraint Guide Replacement - Front Seat HEAD RESTRAINT GUIDE REPLACEMENT - FRONT SEAT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15723 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15724 Head Rest: Removal and Replacement Head Restraint Replacement - Front Seat Head Restraint Replacement - Front Seat Head Restraint Guide Replacement - Front Seat Head Restraint Guide Replacement - Front Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15725 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation Memory Positioning Systems: Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION PERSONALIZATION The following options can be accessed in order by pressing the MENU button anytime while the vehicle is in ON. Pressing the INFO and RESET/SELECT buttons at the same time provides the MENU switch function. Press the MENU button to scroll through each option. All of the personalization options may not be available on your vehicle. Only the options available will be displayed on your driver information center (DIC). Oil Life Monitor Reset - Units Selection (English/Metric) - Remote Start Capability - Horn Chirp During Remote Keyless Entry Locking - Horn Chirp During Remote Keyless Entry Unlocking - Exterior Light Flash During Remote Keyless Entry Locking or Unlocking - Delayed Locking - Automatic Vehicle Unlocking: Specific Doors - Automatic Vehicle Unlocking: When Key is Off or When Shift To Park - Exterior Perimeter Lighting During Remote Keyless Entry Unlock - Security System Passive or Remote Keyless Entry Arming - Select Language: (English, French, Spanish or German) When the desired option is reached, use the ENTER button to toggle between the modes of that option. To make a selection, press the MENU button again. If no selection is made within 10 seconds, the display will revert back to the previous information displayed. The MENU mode is exited when the INFO button is pressed, a 10 second time period has elapsed, the ignition is turned to OFF, or the end of the MENU list is reached. The following display messages may appear on your vehicles driver information center (DIC) by pressing the MENU button: Oil Life Reset: When this option is displayed you can reset the Oil Life Monitor system. To reset the system to 100 percent, press and hold the ENTER button for at least 1 second. An ACKNOWLEDGED display message will appear for 3 seconds or until the next button is pressed. This will tell you the system has been reset. Units: When UNITS appears on the display, press the ENTER button to move between Metric or English. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is English. If you choose English, all information will be displayed in English units. For example, distance in miles and fuel economy in miles per gallon is displayed. If you choose metric, all information will be displayed in metric units. For example, distance in kilometers and fuel economy in liters per 100 kilometers is displayed. The unit measurement will also change the trip odometer, temperature, and average fuel economy displays. Remote Start: The remote start feature, if equipped, can be enabled or disabled. When REMOTE START appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Lock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the LOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Unlock Horn: If your vehicle has remote keyless entry, this feature which allows the vehicle horn to chirp every time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When UNLOCK HORN appears on the display, press the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is OFF. Light Flash: If your vehicle has remote keyless entry, this feature which allows the vehicle exterior perimeter lighting to flash every time the LOCK or UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When LIGHT FLASH appears on the display, press the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Delay Lock: The delayed locking feature, which delays the actual locking of the vehicle, can be enabled or disabled. When DELAY LOCK appears Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Page 15733 on the display, use the ENTER button to move between OFF and ON. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Auto Unlk The automatic door unlocking feature, which allows the vehicle to automatically unlock certain doors, can be enabled or disabled. When AUTO UNLK appears on the display, use the ENTER button to move between: ALL, DRVR, or NONE. When you have made your choice, press and the MENU button to record your selection. The initial setting from the factory is ALL. Unlk: This feature determines when the automatic door unlocking will occur, when either the key is turned to OFF or the vehicle is shifted into PARK (P). When UNLK appears on the display, use the ENTER button to move between KEY OFF and SHIFT TO P. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is SHIFT TO P. EXT Lights: If your vehicle has remote keyless entry, this feature, which allows the vehicle exterior perimeter lighting to turn ON each time the UNLOCK button on the remote keyless entry transmitter is pressed, can be enabled or disabled. When EXT LIGHTS appears on the display, use the ENTER button to move between ON and OFF. When you have made your choice, press the MENU button to record your selection. The initial setting from the factory is ON. Security: If your vehicle has the remote keyless entry system, this feature allows you to select the method used to arm the vehicle security system. When SECURITY appears on the display, use the ENTER button to move between RKE and PASSIVE. When you have made your choice, press the MENU button to record your selection. See Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information. Language: To select your choice of language, use the ENTER button to move between the optional languages. The languages are English, French, German and Spanish. Choosing a language will display all of the information on the DIC in the desired language. When you have made your choice, press the MENU button for at least one second to record your selection. The initial setting from the factory is ENGLISH. Enter: The ENTER button is used to reset certain functions and turn OFF or acknowledge messages on the DIC display. The ENTER button also toggles through the options available in each personalization menu. RADIO PRESET WITH REMOTE KEYLESS ENTRY The vehicle may be equipped with a radio personalization feature. This feature allows you to store radio preset stations to the remote keyless entry transmitter used to unlock the doors. Two drivers can store different preset stations and the radio recalls the stored radio settings associated with a particular transmitter. When UNLOCK is pressed on the remote, the preset stations that the driver stored is recalled. Refer to Radio/Audio System Description and Operation in Radio, Stereo, and Compact Disc for more information about the radio. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Actuator Replacement - Manual Power Seat Motor: Service and Repair Lumbar Actuator Replacement - Manual LUMBAR ACTUATOR REPLACEMENT - MANUAL Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Actuator Replacement - Manual > Page 15738 Power Seat Motor: Service and Repair Lumbar Replacement - Front Seat Lumbar Replacement - Front Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair Seat Back Frame: Service and Repair SEAT BACK FRAME REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Page 15743 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose Seat Cover: Customer Interest Interior - Seat Cushion Cover Loose TECHNICAL Bulletin No.: 06-08-50-005D Date: July 23, 2010 Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings) Models: 2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn ION Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories). Condition Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is loose. Cause This condition may be caused by the J-strip seat cover retaining feature releasing from the seat frame. Correction 1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI. Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009 Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step 2.) 2. Reattach the J-strip to the seat frame. 3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page 15752 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15758 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15759 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose Seat Cover: All Technical Service Bulletins Interior - Seat Cushion Cover Loose TECHNICAL Bulletin No.: 06-08-50-005D Date: July 23, 2010 Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings) Models: 2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn ION Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories). Condition Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is loose. Cause This condition may be caused by the J-strip seat cover retaining feature releasing from the seat frame. Correction 1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI. Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009 Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step 2.) 2. Reattach the J-strip to the seat frame. 3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page 15764 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15769 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15770 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 05560 > Sep > 05 > Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Fluid - M/T: All Technical Service Bulletins Campaign - Getrag 5 Speed M/T Fluid Fill (Canada) Transmission Fluid Fill # 05560 - (Sep 15, 2005) Models: Certain 2005-06 Chevrolet Cobalt and Pontiac Pursuit (Canada only) Equipped with Getrag 5-Speed Manual Transmission (RPO M86) An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible, but no later than November 30, 2005, at which time this bulletin will expire. Condition Some late production 2005 and early production 2006 Chevrolet Cobalt and Pontiac Pursuit (Canada only) model vehicles with RPO M86 5 Speed manual transmissions were not filled with the specified Dexron III transmission fluid. Correction Dealers are to replace the transmission fluid in dealer stock vehicles with Dexron III transmission fluid. Service Procedure Refer to SI document number 869140 for the manual transmission fluid replacement procedure. Parts Information Warranty Information Dealers This correction should be performed on all vehicles currently in your inventory that are included in the VIN list contained in the Administrative Message (GM US) Dealer Communication (Canada) prior to sale or delivery. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose Seat Cushion: Customer Interest Interior - Seat Cushion Cover Loose TECHNICAL Bulletin No.: 06-08-50-005D Date: July 23, 2010 Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings) Models: 2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn ION Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories). Condition Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is loose. Cause This condition may be caused by the J-strip seat cover retaining feature releasing from the seat frame. Correction 1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI. Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009 Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step 2.) 2. Reattach the J-strip to the seat frame. 3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page 15789 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose Seat Cushion: All Technical Service Bulletins Interior - Seat Cushion Cover Loose TECHNICAL Bulletin No.: 06-08-50-005D Date: July 23, 2010 Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings) Models: 2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn ION Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories). Condition Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is loose. Cause This condition may be caused by the J-strip seat cover retaining feature releasing from the seat frame. Correction 1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI. Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009 Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step 2.) 2. Reattach the J-strip to the seat frame. 3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page 15795 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures Seat Cushion: Procedures Seat Cushion Outer Trim Panel Replacement - Front Seat SEAT CUSHION OUTER TRIM PANEL REPLACEMENT - FRONT SEAT Seat Cushion Heater Element Replacement - Front SEAT CUSHION HEATER ELEMENT REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15798 Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15799 Seat Cushion Cover and Pad Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15800 SEAT CUSHION COVER AND PAD REPLACEMENT - FRONT Seat Cushion Replacement - Rear SEAT CUSHION REPLACEMENT - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15801 Seat Cushion Cover and Pad Replacement - Rear SEAT CUSHION COVER AND PAD REPLACEMENT - REAR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15802 Seat Cushion Inner Trim Panel Replacement SEAT CUSHION INNER TRIM PANEL REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15803 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15804 Seat Cushion: Removal and Replacement Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15805 Seat Cushion Cover and Pad Replacement - Front Seat Cushion Cover and Pad Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15806 Seat Cushion Replacement - Rear Seat Cushion Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15807 Seat Cushion Outer Trim Panel Replacement - Front Seat Seat Cushion Outer Trim Panel Replacement - Front Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15808 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams Seat Heater: Diagrams Heated Seat Element Driver Back (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 15812 Heated Seat Element Passenger Back (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 15813 Heated Seat Element Driver Cushion (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 15814 Heated Seat Element Passenger Cushion (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 15815 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION The heated seat system consists of the following components: - Heated Seat Switch - Heated Seat Control Module - Seat Cushion Heater Element - Seat Back Heater Element - Temperature Sensor - DIC/HVAC Fuse 10A - HSEAT/LUM Fuse 15A Heated Seat Switch The heated seat switch controls the high an low temperature settings through a rocker switch that is located in the center console. Battery positive voltage is supplied to the switch through the IGN 3 voltage circuit and the DIC/HVAC Fuse located in the I/P fuse block. The heated seat system will operate only with the ignition in the ON position. Heated Seat Module The heated seat module controls the flow of battery positive voltage used to heat the seat heating elements. Battery positive voltage is supplied at all times to the heated seat module through the battery positive circuit and the H SET/LUM Fuse located in the I/P fuse block. The heated seat module and the seat heating elements are grounded through the module ground circuit to G301. Heated Seat Operation When the heated seat switch is placed in the high or low temperature position, battery positive voltage is applied through the heated seat switch signal circuit to the heated seat module. In response to this signal, the heated seat module closes it's contacts and applies battery positive voltage through the heated seat element supply voltage to the heating elements. With the heated seat switch in the high position, battery positive voltage is applied through a 310 ohm resister in the switch and the heated seat high/low signal circuit to the heated seat module. In response to this signal, the module sets the temperature to high heat. When the heated seat switch is placed in the low position, battery positive voltage is applied through a 200 ohm resister in the switch and the heated seat high/low signal circuit to the module. In response to this signal, the module sets the temperature to low heat. Temperature Regulation The heated seat system is designed to warm the seat cushion and seat back to approximately 44°C (111.2°F) when in the high heat mode, or 37°C (98.6°F) when in the low heat mode. The heated seat module monitors the seat temperature through the temperature sensor signal circuit and the temperature sensor (thermistor) that is located in the seat cushion. The temperature sensor is a variable resistor, it's resistance changes as the temperature of the seat changes. When the temperature sensor resistance indicates to the heated seat module that the seat cushion has reached the desired temperature, the module opens its contacts to remove voltage from the heating elements. The heated seat module will then cycle the contacts open and closed to maintain the desired temperature. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Back Heater Element Replacement - Front Seat Heater: Service and Repair Seat Back Heater Element Replacement - Front Seat Back Heater Element Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Back Heater Element Replacement - Front > Page 15818 Seat Heater: Service and Repair Seat Cushion Heater Element Replacement - Front Seat Cushion Heater Element Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement Seat Heater Control Module: Technical Service Bulletins Interior - Revised Seat Heater Module Replacement Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Front Heated Seat Control Module Replacement procedure in the Seats sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Interior - Revised Seat Heater Module Replacement > Page 15823 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15824 Seat Heater Control Module: Locations Driver Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15825 Passenger Seat Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15826 Seat Heater Control Module: Diagrams Heated Seat Module - Driver (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15827 Heated Seat Module - Passenger (With RPO Code KA1) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures The content of this article/image reflects the changes identified in TSB 05-08-50-011 Bulletin No.: 05-08-50-011 Date: September 16, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Heated Seat Control Module Replacement Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) It is not necessary to remove the front seat in order to replace the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 15830 Heated Seat Control Module Replacement - Front Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 15831 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 15835 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 15836 Seat Heater Switch: Diagrams Heated Seat Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 15837 Heated Seat Switch = Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 15840 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement Seat Latch: Technical Service Bulletins Interior - Revised Front Seat Adjuster Replacement Bulletin No.: 06-08-50-001 Date: January 20, 2006 SERVICE MANUAL UPDATE Subject: Revised Seat Adjuster Replacement - Front Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Seat Adjustment Replacement - Front procedure in the Seats sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement > Page 15845 The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement > Page 15846 Seat Latch: Technical Service Bulletins Interior - Seat Back Latch Replacement Addition Bulletin No.: 05-08-50-016 Date: December 13, 2005 SERVICE MANUAL UPDATE Subject: Addition of Seat Back Release Latch Replacement - Rear Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) This bulletin is being issued to add the Seat Back Release Latch Replacement - Rear procedure in the Seats sub-section of the Service Manual. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Seat Back Release Latch Replacement - Rear Removal Procedure 1. Remove the fastener (1) from the lower lock pillar garnish molding. Sedan shown, coupe similar. Fold the garnish trim away from the latch. 2. Remove the latch bolts. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement > Page 15847 3. Disengage the clip holding the latch release handle to the rear compartment shelf. 4. Remove the rosebud fastener which retains the latch cable to the rear compartment shelf. 5. Remove the grommet from the sheet metal. 6. Pull the latch assembly into the passenger compartment. 7. Remove the latch assembly from the vehicle. Installation Procedure 1. Install the latch assembly. 2. Feed the cable and the release handle through the sheet metal to the rear compartment. Note: Refer to Fastener Notice in Cautions and Notices. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement > Page 15848 3. Install the rear seat back latch bolts. Tighten Tighten the bolts to 12 N.m (106 lb in). 4. Install the grommet. 5. Install the rosebud fastener to the latch assembly cable. 6. Install the release handle and engage the handle in the clip. 7. Install the lower lock pillar garnish molding fastener (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Interior - Revised Front Seat Adjuster Replacement > Page 15849 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Page 15850 Seat Latch: Service and Repair The content of this article reflects the changes identified in TSB- 05-08-50-016 Dated: December 13, 2005 Seat Back Release Latch Replacement Removal Procedure 1. Remove the fastener (1) from the lower lock pillar garnish molding. Sedan shown, coupe similar. Fold the garnish trim away from the latch. 2. Remove the latch bolts. 3. Disengage the clip holding the latch release handle to the rear compartment shelf. 4. Remove the rosebud fastener, which retains the latch cable to the rear compartment shelf. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Page 15851 5. Remove the grommet from the sheet metal. 6. Pull the latch assembly into the passenger compartment. 7. Remove the latch assembly from the vehicle. Installation Procedure 1. Install the latch assembly. 2. Feed the cable and the release handle through the sheet metal to the rear compartment. 3. Install the rear seat back latch bolts. Tighten the bolts to 12 N.m (106 lb in). 4. Install the grommet. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Page 15852 5. Install the rosebud fastener to the latch assembly cable. 6. Install the release handle and engage the handle in the clip. 7. Install the lower lock pillar garnish molding fastener (1). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 15857 Door Lock Switch - Passenger (With RPO Code AU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 15858 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Outside Rearview Mirror Switch (With RPO Code DG7) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 15864 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 15868 Rear Compartment Lid Release Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 15872 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 15873 Seat Heater Switch: Diagrams Heated Seat Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 15874 Heated Seat Switch = Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 15877 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: Customer Interest Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 15886 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose Sunroof / Moonroof Switch: All Technical Service Bulletins Interior - Sunroof Switch Bezel Coming Loose Bulletin No.: 05-08-110-006B Date: December 17, 2007 TECHNICAL Subject: Sunroof Switch Bezel Comes Loose From Headliner (Replace Bezel and Retainer, If Necessary) Models: 2005-2008 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007-2008 Pontiac G5 Supercede: This bulletin is being revised to correct the models involved. Please discard Corporate Bulletin Number 05-08-110-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sunroof switch bezel comes loose from the headliner. Cause This condition may be caused by a broken sunroof switch bezel tab. Correction Inspect the sunroof switch bezel retainer. If it appears to be bent, deformed or mutilated, replace the retainer with a new one. Replace the sunroof switch bezel. Firmly push the sunroof switch and bezel into the headliner module in order to secure the bezel to the retainer. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Switch: > 05-08-110-006B > Dec > 07 > Interior - Sunroof Switch Bezel Coming Loose > Page 15892 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 15893 Headliner Components (With RPO Code CF5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Technical Service Bulletins > Page 15894 Sunroof Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. INSTALLATION PROCEDURE 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 15897 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the clips located at the sides of the switch bezel. 2. Rotate the switch bezel (1) down and to the left to remove it from the headliner. 3. Disconnect the electrical connector from the sunroof control switch. 4. Remove the sunroof control switch (2) from the bezel. Installation Procedure 1. Install the sunroof control switch (2) to the bezel (1). 2. Connect the electrical to the switch. 3. Rotate the sunroof control switch and bezel into the headliner and press to engage the clips. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Sound Proofing / Insulation: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15906 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15907 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15908 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15909 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15910 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15911 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15912 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Sound Proofing / Insulation: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15918 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15919 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15920 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15921 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15922 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15923 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 15924 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15930 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15931 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15932 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 15937 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 06-03-10-010A > Jun > 10 > Wheels Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 06-03-10-010A > Jun > 10 > Wheels Changing Procedures/Precautions > Page 15942 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 06-03-10-010A > Jun > 10 > Wheels Changing Procedures/Precautions > Page 15943 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM Wheels: All Technical Service Bulletins Wheels/Tires - 18 Inch Wheels Available Through GM INFORMATION Bulletin No.: 05-03-10-011E Date: May 26, 2010 Subject: 18 Inch Accessory Wheels Available Through GM Accessories Models: 2005-2007 Chevrolet Cobalt SS Supercharged 2006-2008 Chevrolet Cobalt SS (2 Door Coupe and 4 Door Sedan - Excludes Turbocharged) 2007-2011 Chevrolet HHR, HHR Panel (LT Option with 17" Tires (RPO QBV) Only) (Built After VIN Breakpoint 7S541326) 2006 Pontiac Pursuit GT (Canada Only), G4 GT (Mexico Only) 2007-2010 Pontiac G5 GT Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-03-10-011D (Section 03 - Suspension). The purpose of this bulletin is to provide a reference guide for the technician to upgrade a vehicle from factory wheel and tires to 18" wheels and tires, which are available through GM Accessories. This guide will cover tires, wheels, vehicle modifications, and warranty information. Tires GM offers one tire, the Pirelli P-ZERO ROSSO 215/45R18, to be used in conjunction with the 18" accessory wheels. The Pirelli tire has a Tire Performance Criteria (TPC) spec of #1255, which meets or exceeds all federal safety guidelines. Wheels Center Cap Notice Attempting to "hammer on" the caps may result in damage to the cap. Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is by hand. As an alternate, use a non-metallic object to push the center cap into place. Wheel (Lug) Nuts Caution: Incorrect wheel nuts or improperly tightened wheel nuts may cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be tightened to 140 Nm (100 lb ft) using the tightening sequence illustrated above. The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15948 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15949 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15950 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 15955 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 15956 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 15957 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-003F > Apr > 10 > Tires/Wheels Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-003F > Apr > 10 > Tires/Wheels Low Tire/Leaking Cast Aluminum Wheels > Page 15962 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 15967 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 15968 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 15969 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 04-03-10-012B > Feb > 08 > Wheels Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15979 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15980 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-002F > Apr > 11 > Wheels Chrome Wheel Staining/Pitting/Corrosion > Page 15981 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 15986 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 06-03-10-010A > Jun > 10 > Wheels Changing Procedures/Precautions > Page 15991 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 06-03-10-010A > Jun > 10 > Wheels Changing Procedures/Precautions > Page 15992 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15997 Care/Cleaning Use soap, hot water and a 100% cotton cloth to clean and polish the new wheels. If using a wheel cleaner, be sure to select one that will not harm the wheel surface, such as GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use 10953202). Avoid car washes that use carbide tipped brushes, as these may damage the wheel's finish. Periodically clean the backside of the wheel to remove road grime, brake dust and grease. Balancing Use MC-style balance weights on the inboard rim and stick-on weights mounted on the outboard-center of the rim (behind the spokes). Vehicle Modifications BCM Reprogramming Important: BCM reprogramming not required on the Chevrolet Cobalt SS Supercharged and the Chevrolet HHR. For proper vehicle operation and to ensure coverage under the provisions of the New Vehicle Limited Warranty, the vehicle must be reprogrammed with the correct calibration as soon as accessory wheels are installed. After initiating the BCM setup procedure with the Tech 2(R), select "Change Options" then "Select Wheel Size". The wheel size selections will then be displayed. Note that the current wheel size and tire RPO (17" QBU) will be highlighted. The new wheel size and tire RPO (18" QTJ) should then be selected from the list to program the correct calibration. Select "Save Options" on each of the remaining screens until completed. Important: If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the BCM to the original specifications. Tire Label Important All tire and wheel packs are shipped with two different tire labels. The following is a breakdown on when each label should be used - dependent upon the model: - Chevrolet Cobalt SS Supercharged vehicles DO NOT need a new label. - Cobalt/G5/Pursuit/G4 - Use tire label P/N 19165892 (road tire pressure of 220 kPa (32 psi)). - HHR - Use tire label P/N 19201200 (road tire pressure of 241 kPa (35 psi)). After installing the recommended 215/45R18 tires, place the provided tire label on the vehicle. The new tire label should be located within the red box, over the top of the original tire label found on the door jamb. To locate the label within the red box, use the upper and left hand edge of the red line as a guide. When properly placed, the new tire label will obscure the original tire information. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (65°F). The label is provided as a guide for tire inflation pressures. Tire Pressure Monitoring (TPM) System To avoid system malfunctions, it is necessary to install tire pressure sensors in the accessory wheels. After the wheels are installed on the vehicle, it is necessary to learn the new sensor identification codes/locations into the remote control door lock receiver (RCDLR). Please refer to the proper re-learn procedure in SI. Warranty Information Wheels Part and labor expense to install GM Accessory Wheels as well as labor to program any affected modules "IS NOT" covered under the terms of the Bumper to Bumper Warranty. All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER new vehicle delivery, or are replaced under the new vehicle warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor / Installer). For Canada, in the event GM Accessories are installed AFTER new vehicle delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15998 Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003C. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-011E > May > 10 > Wheels/Tires 18 Inch Wheels Available Through GM > Page 15999 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 16004 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 16005 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 00-03-10-006F > May > 10 > Wheels/Tires Tire Radial Force Variation (RFV) > Page 16006 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 05-03-10-003F > Apr > 10 > Tires/Wheels Low Tire/Leaking Cast Aluminum Wheels > Page 16011 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 16016 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 16017 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sound Proofing / Insulation: > 08-03-10-006C > Apr > 10 > Tires/Wheels Tire Slowly Goes Flat/Warning Light ON > Page 16018 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair Splash Guard: Service and Repair Splash Shield Replacement - Engine Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Spoiler Replacement - Rear Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns Front Strut / Shock Tower: Customer Interest Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16039 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16040 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16041 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16042 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16043 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16044 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension Front Suspension Noise Concerns > Page 16045 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns Front Strut / Shock Tower: All Technical Service Bulletins Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16051 If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16052 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16053 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16054 Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16055 Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16056 - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 04-03-08-006E > Nov > 10 > Suspension - Front Suspension Noise Concerns > Page 16057 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16058 Front Strut / Shock Tower: By Symptom Technical Service Bulletin # 04-03-08-006E Date: 101101 Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16059 sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16060 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16061 Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16062 Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16063 Warranty Information #5 Condition #6 (FE1 Suspension Only) Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16064 Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16065 Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Disclaimer Technical Service Bulletin # 04-03-08-006E Date: 101101 Suspension - Front Suspension Noise Concerns TECHNICAL Bulletin No.: 04-03-08-006E Date: November 01, 2010 Subject: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair) Models: 2005-2010 Chevrolet Cobalt (Including SS) 2006-2010 Chevrolet HHR (Including SS) 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 2003-2007 Saturn ION Supercede: This bulletin is being revised to add 2010 model year and update Condition #7 with new part information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 Suspension). This bulletin provides information on eight different steering/front suspension noise conditions. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16066 Condition #1 Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface. This condition can be duplicated by the technician using the following procedure: 1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable. 2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition. 3. Remove the 60 amp EPS fuse (1) in the underhood fuse block. 4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism). 5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel. Correction #1 If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column. Important The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack. If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #1 For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only) Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16067 This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking. Correction #2 Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft. 1. Clean the surface area of the upper spring seat using fine sandpaper. 2. Apply a light coat *of 3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes. 3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M(TM) Duramix(TM) Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature. 4. Apply a light coat of *3M(TM) Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes. 5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16068 For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog. Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces. Cause #3 This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture. Correction #3 Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16069 Condition #4 Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90° of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. The following are characteristics of this noise: - This noise is very random. - This noise is independent of the steering wheel angle and independent of the bumpiness of the road. - This noise is a low frequency dull one and can be felt in your feet. - This noise can normally be heard from the driver seat. - This noise can be felt upon touching the steering gear from outside of the vehicle. Note You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it. Cause #4 This condition may be caused by inadequate lubrication of the steering intermediate shaft. Correction #4 Important DO NOT replace the steering gear or steering column assembly. Replace the intermediate shaft. Important If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Parts Information #4 Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps. Correction #5 The following steps have been found to be very effective in removing this condition. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16070 1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam. 2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat. Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Warranty Information #5 Condition #6 (FE1 Suspension Only) Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking. Cause #6 This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months. Correction #6 If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16071 If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise. Parts Information #6 Warranty Information #6 For vehicles repaired under warranty, use: Condition #7 Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement. Cause #7 (Saturn ION Only) This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp. Correction #7 (Saturn ION Only) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps: Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. - On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. - On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Saturn ION Only) Cause #7 (Cobalt, G5, HHR) This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft insulators (bushings). Correction #7 (Cobalt, G5, HHR) Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16072 1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI. Important Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type. 2. If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI. 3. Verify the repair by repeating Step 1. Parts Information #7 (Cobalt, G5, HHR) Warranty Information #7 For vehicles repaired under warranty, use: Condition #8 Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below. Correction #8 Important DO NOT replace the steering column. Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 16073 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Pull the hood rear seal from the air inlet grille panel to remove it. 2. Remove the wiper arms. 3. Remove the push pin fasteners in the air inlet grille panel. 4. Disconnect the washer fluid hose. 5. Remove the air inlet grille panel from the vehicle. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 16079 6. Remove the washer nozzles from the air inlet grille panel. Installation Procedure 1. Install the washer nozzles to the air inlet grille panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 16080 2. Position the air inlet grille panel to the vehicle. 3. Connect the washer fluid hose. 4. Install the push pin fasteners to the air inlet grille panel. 5. Install the wiper arms. 6. Install the hood rear seal to the air inlet grille panel and press it into position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Upper Auxiliary Weatherstrip Replacement - Front Door Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 16086 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening (Coupe) Weatherstrip Replacement - Door Opening (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 16087 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening (Sedan) Weatherstrip Replacement - Door Opening (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Front Door Upper Auxiliary > Page 16088 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 16093 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Inner Front Side Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 16094 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Side Seal Replacement - Hood Rear Side Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal, located at the end of the plenum to hood seal, from the fender. 3. Remove the seal from the vehicle. 4. Clean any adhesive from the pinch-weld flange and hood hinge using 3M(TM) P/N 8984. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side > Page 16099 2. With the rear side hood seal butted to the plenum to hood seal, press the side hood seal until the adhesive is fully adhered. 3. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Rear Side > Page 16100 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Pull the hood rear seal from the air inlet screen. Installation Procedure 1. Position the hood rear seal to the vehicle. 2. Push the hood rear seal onto the air inlet screen in order to fully seat the seal. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front and Rear Side Door - Upper Auxiliary Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement > Page 16108 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16121 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical Cruise Control Inop/No Start Condition > Page 16127 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16128 Brake Switch (Cruise Control): Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16129 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16130 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard.The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 1. The release switch (1) 2. The stop lamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16131 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the cruise control release switch. 2. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. Refer to Cruise Release Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16140 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16146 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove, Binds Or Sticks TECHNICAL Bulletin No.: 09-02-35-005C Date: February 07, 2011 Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) Models: 2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit (Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to April 24, 2009) Supercede: This bulletin is being revised to remove an Attention statement, update the build date for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B (Section 02 - Steering). Condition Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder. Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16156 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16157 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16158 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 05-02-35-007A > Oct > 06 > Ignition - Inadvertent Turning of Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Inadvertent Turning of Ignition Lock Cylinder Bulletin No.: 05-02-35-007A Date: October 25, 2006 INFORMATION Subject: Information on Inadvertent Turning of Key Cylinder, Loss of Electrical System and No DTCs Models: 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 2006-2007 Pontiac Solstice 2003-2007 Saturn ION 2007 Saturn Sky Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 05-02-35-007 (Section 02 - Steering). There is potential for the driver to inadvertently turn off the ignition due to low ignition key cylinder torque/effort. The concern is more likely to occur if the driver is short and has a large and/or heavy key chain. In these cases, this condition was documented and the driver's knee would contact the key chain while the vehicle was turning and the steering column was adjusted all the way down. This is more likely to happen to a person who is short, as they will have the seat positioned closer to the steering column. In cases that fit this profile, question the customer thoroughly to determine if this may the cause. The customer should be advised of this potential and should take steps to prevent it - such as removing unessential items from their key chain. Engineering has come up with an insert for the key ring so that it goes from a "slot" design to a hole design. As a result, the key ring cannot move up and down in the slot any longer - it can only rotate on the hole. In addition, the previous key ring has been replaced with a smaller, 13 mm (0.5 in) design. This will result in the keys not hanging as low as in the past. Parts Information Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Stuck in Ignition Lock Cylinder Bulletin No.: 06-02-35-004 Date: February 02, 2006 TECHNICAL Subject: Ignition Key Stuck (Replace Shifter Assembly or Ignition Lock Cylinder Assembly) Models: 2005-2006 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) Condition Some customers may comment that they cannot remove the key from the ignition. Cause 1 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. Cause 2 Metal flashing left in the cylinder may cause this condition. Correction 1 Replace the shifter assembly. Correction 2 Replace the ignition lock cylinder. Parts Information Warranty Information Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 16167 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 05-00-89-071 > Oct > 05 > Ignition System - Revised Key & Lock Cylinder Coding Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition System - Revised Key & Lock Cylinder Coding Bulletin No.: 05-00-89-071 Date: October 21, 2005 SERVICE MANUAL UPDATE Subject: Revised Key and Lock Cylinder Coding Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) This bulletin is being issued to revise the Key and Lock Cylinder Coding information in the General Information sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the key cutting and lock cylinder coding procedure, refer to the instruction sheet supplied in the key and lock cylinder kit. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16181 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16182 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16183 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 06-02-35-004 > Feb > 06 > Ignition - Key Stuck in Ignition Lock Cylinder > Page 16192 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Customer Interest for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16209 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Switch (Cruise Control): All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16215 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16216 Brake Switch (Cruise Control): Diagrams Brake Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16217 Brake Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16218 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard.The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 1. The release switch (1) 2. The stop lamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 16219 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the cruise control release switch. 2. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. Refer to Cruise Release Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16228 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16234 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16243 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16244 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16245 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16246 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16247 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16248 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16249 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16250 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16251 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16252 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16253 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16254 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16255 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16256 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16257 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16258 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16259 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16260 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16261 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16262 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16263 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16264 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16265 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16266 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16267 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16268 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16269 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16270 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16271 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16272 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16273 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16274 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16275 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16276 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16277 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16278 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16279 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16280 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16281 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16282 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16283 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16284 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16285 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16286 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16287 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16288 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16289 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16290 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16291 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16292 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16293 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16294 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16295 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16296 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16297 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16298 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16299 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16300 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16301 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16302 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16303 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16304 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16305 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16306 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16307 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16308 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16309 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16310 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16311 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16312 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16313 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16314 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16315 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 16316 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 16317 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The instrument panel cluster (IPC) generates the audible warnings through a speaker. The IPC receives audible warning requests via the GMLAN serial data line. If the IPC receives multiple audible warning requests, the warning with the highest priority sounds first. The following lists the audible warning priority and the pulse rate: - Fast rate chime (200 pulses per minute) - Medium rate chime (150 pulses per minute) - Slow rate chime (50 pulses per minute) - Single chime Fasten Safety Belt Warning The instrument panel cluster (IPC) activates the fasten safety belt audible warning as requested by the body control module (BCM). The BCM sends a GMLAN message to the IPC indicating the chime frequency (slow rate) and duration (8 seconds). The fasten safety belt warning sounds and the fasten safety belt indicator illuminates when the following occurs: The ignition switch transitions to ON. - The BCM detects that the driver seat belt is not buckled (signal circuit is low). The IPC receives a GMLAN message from the BCM indicating the driver seat belt status. If the seat belt is buckled when the ignition is turned on, the chime does not sound. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to ON, the chime does not sound. Key-In-Ignition Warning The instrument panel cluster (IPC) activates the key-in-ignition audible warning as requested by the body control module (BCM). The BCM sends a GMLAN message to the IPC indicating the chime frequency (medium rate) and duration (continuous). The key-in-ignition warning sounds when the following occurs: The ignition switch is OFF. - The BCM determines that the driver door is open (signal circuit is low). - The BCM determines that the ignition key alarm switch is closed (signal circuit is low). Lights On Warning The instrument panel cluster (IPC) activates the lights on warning as requested by the body control module (BCM). The BCM sends a GMLAN message to the IPC indicating the chime frequency (fast rate) and duration (continuous). The lights on warning sounds when the following occurs: The ignition is OFF. - The BCM determines that the driver door is open (signal circuit is low). - The BCM determines that the headlamp switch is in the PARK or HEAD position. Park Brake Warning The instrument panel cluster (IPC) activates the park brake audible warning as requested by the body control module (BCM). The BCM sends a GMLAN message to the IPC indicating the chime frequency (fast rate) and duration (continuous). The park brake warning sounds and the brake indicator illuminates when the following occurs: - The ignition is ON. - The vehicle speed is greater than 5 km/h (3.1 mph). The BCM receives a GMLAN message from the powertrain control module (PCM) indicating the vehicle speed. - The BCM determines that the park brake is engaged (signal circuit is low). Turn Signal On Warning The instrument panel cluster (IPC) activates the turn signal on audible warning as requested by the body control module (BCM). The BCM sends a GMLAN message to the IPC indicating the chime frequency (single chime in phase with turn signal indicator) and duration (continuous). The turn signal on warning sounds when the following occurs: The ignition is ON. - The BCM detects that the turn signal is active for greater than 1.2 km (0.75 mi). The BCM calculates the distance based on a class 2 message from the powertrain control module (PCM) indicating the vehicle speed. Additional Warnings The following warnings have an associated instrument panel cluster (IPC) indicator: Antilock Brake System - Air Bag - Brake Warning - Charging System - High Engine Coolant Temperature - Low Fuel - Low Engine Oil Pressure - Service Vehicle Soon Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 16318 The body control module (BCM) sends a GMLAN message to the IPC indicating the chime frequency (medium rate) and duration (3 seconds). The warning sounds once per ignition cycle when an indicator illuminates and the engine is running for greater than 6.5 seconds. For a description of each indicator, refer to Indicator/Warning Message Description and Operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Boost Gauge - Supercharger > Component Information > Technical Service Bulletins > Instruments - Supercharger Boost Indicator Replacement Boost Gauge - Supercharger: Technical Service Bulletins Instruments - Supercharger Boost Indicator Replacement Bulletin No.: 05-08-49-025 Date: September 21, 2005 SERVICE MANUAL UPDATE Subject: Addition of Supercharger Boost Air Pressure Indicator Replacement Procedure Models: 2005 Chevrolet Cobalt This bulletin is being issued to add the Supercharger Boost Air Pressure Indicator Replacement procedure in the Instrument Panel, Gages, and Console sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Boost Gauge - Supercharger > Component Information > Technical Service Bulletins > Instruments - Supercharger Boost Indicator Replacement > Page 16323 Supercharger Boost Air Pressure Indicator Replacement Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Boost Gauge - Supercharger > Component Information > Technical Service Bulletins > Page 16324 Supercharger Boost Gage Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Boost Gauge - Supercharger > Component Information > Technical Service Bulletins > Page 16325 Boost Gauge - Supercharger: Service and Repair The content of this article reflects the changes found in TSB 05-08-49-025 Bulletin No.: 05-08-49-025 Date: September 21, 2005 SERVICE MANUAL UPDATE Subject: Addition of Supercharger Boost Air Pressure Indicator Replacement Procedure Models: 2005 Chevrolet Cobalt Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Boost Gauge - Supercharger > Component Information > Technical Service Bulletins > Page 16326 Supercharger Boost Air Pressure Indicator Replacement Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16331 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16332 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16333 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16334 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16335 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16336 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16337 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16338 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16339 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16340 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16341 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16342 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16343 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16344 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16345 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16346 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16347 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16348 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16349 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16350 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16351 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16352 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16353 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16354 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16355 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16356 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16357 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16358 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16359 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16360 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16361 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16362 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16363 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16364 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16365 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16366 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16367 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16368 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16369 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16370 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16371 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16372 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16373 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16374 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16375 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16376 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16377 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16378 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16379 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16380 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16381 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16382 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16383 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16384 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16385 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16386 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16387 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16388 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16389 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16390 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16391 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16392 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16393 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16394 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16395 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16396 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16397 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16398 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16399 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16400 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16401 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16402 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16403 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16404 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16405 Brake Warning Indicator: Electrical Diagrams Brake Warning System Schematics Brake Warning System Diagram Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 16406 Locations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams Cigar Lighter (With RPO CodeDT4) Auxiliary Power Outlet (Without RPO Code DT4) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 16410 Cigarette Lighter: Service and Repair CIGAR LIGHTER HOUSING OR 12 VOLT ACCESSORY POWER RECEPTACLE REPLACEMENT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window.You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 16411 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16417 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16418 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16419 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16420 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16421 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16422 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16423 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16424 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16425 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16426 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16427 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16428 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16429 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16430 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16431 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16432 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16433 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16434 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16435 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16436 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16437 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16438 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16439 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16440 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16441 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16442 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16443 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 16447 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 16448 I/P Dimmer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 16449 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 16453 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 16454 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 16455 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 16459 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 16460 Driver Information Center (DIC) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 16461 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) displays important vehicle information when it first powers up. The DIC is also used to display Odometer and Outside Air Temperature when other important vehicle information is not being displayed. The DIC switches are hardwired to and read by the IPC. The BCM is responsible for driving and processing the DIC display through GMLAN serial data. The BCM is responsible for reading the outside air temperature (OAT) and season odometer. The outside air temperature and season odometer is transmitted to the IPC over GMLAN for display in the DIC. The OAT data is transmitted in degrees Celsius and the cluster is responsible for converting the outside air temperature (OAT) to Fahrenheit. There are 2 DIC buttons on the instrument panel cluster (IPC): - INFO - RESET/SELECT The 2 DIC buttons however provide 3 switch functions. Pressing the INFO and RESET/SELECT button at the same time provides the MENU switch function. INFO The INFO button is used in order to navigate through the following driver information center (DIC) information modes: AV VEHICLE SPEED - AV FUEL ECON - COOLANT TEMPERATURE - FUEL RANGE - OIL LIFE MONITOR - TRIP ODOMETER A - TRIP ODOMETER B Other instrument panel cluster (IPC) information displayed in the DIC are Season odometer and Outside Air Temp. AV VEHICLE SPEED Average speed is calculated using the equation: Average Speed = Distance/Ignition On. Distance = The accumulated distance travelled since the last reset of this value. - Ignition On = The accumulated ignition on time since the last reset of this value. Ignition on time is measured from the time that the ignition is turned ON to the time when the ignition is turned OFF. The value of this mode is retained during ignition OFF. Press and hold the RESET/SELECT button on the DIC for 1 second in order to reset the average speed display. AV FUEL ECON Average fuel economy is calculated using the equation: AFE = Distance/Fuel. Distance = The accumulated distance travelled since the last reset of this value. - Fuel = The accumulated fuel consumption since the last reset of this value. The DIC receives a serial data message from the body control module (BCM) regarding fuel usage information. The value of this mode is retained during ignition OFF and can be changed between English units and metric units. Press and hold the RESET/SELECT button on the DIC switch for 1 second in order to reset the ECON display. COOLANT TEMPERATURE The DIC receives GMLAN serial data message from the BCM requesting the display of the coolant temperature. The coolant temperature is sent to the BCM as determined by the powertrain control module (PCM)/engine control module (ECM) via GMLAN serial data message. FUEL RANGE This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last reset of the value. Fuel Range is calculated using the equation: Fuel Range = Distance Sum/Fuel Sum. Distance Sum = The accumulated distance travelled since the last reset of this value. - Fuel Sum = The accumulated fuel delivered since the last reset of this value. The DIC receives a GMLAN serial data message from the BCM with fuel information. The value of this mode is retained during ignition OFF and can be changed between English units and metric units. The FUEL RANGE display cannot be reset. OIL LIFE MONITOR The PCM/ECM sends the oil life remaining percentage to the body control module (BCM) via a GMLAN serial data message. The DIC receives a serial data message from the BCM indicating the remaining oil life. The DIC displays the current percentage of the GM Oil Life System as determined by the PCM/ECM. TRIP ODOMETER A and TRIP ODOMETER B Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 16462 The DIC displays vehicle trip odometer mileage based on the vehicle speed signal (VSS) from the body control module (BCM). The trip odometer displays accumulated km (mi) since the last reset of this value. The trip odometer is capable of displaying up to 999.9 km (999.9 mi). Trip odometer information is not retained when the battery is disconnected. Press and hold the INFO button on the DIC for 1 second in order to reset the trip odometer display. RESET/SELECT The RESET/SELECT button is used in order to acknowledge a warning message, reset an option, or to select an option. Press and hold for 0.25 seconds to perform RESET/SELECT. MENU The MENU button is used in order to navigate through the following personalization modes: AUTO UNLK - DELAY LOCK - EXT LIGHTS - LANGUAGE - LIGHT FLASH - LOCK HORN - OIL-LIFE RESET - REMOTE START - SECURITY - UNITS - UNLOCK HORN OIL-LIFE RESET The powertrain control module (PCM)/engine control module (ECM) sends the oil life remaining percentage to the body control module (BCM) via a GMLAN serial data message. The driver information center (DIC) receives a GMLAN serial data message from the BCM indicating the remaining oil life. The DIC displays the current percentage of the GM Oil Life System as determined by the PCM/ECM. When the oil life remaining percentage drops below 10 percent, the DIC displays CHANGE ENGINE OIL. When the engine oil is changed, reset the engine oil life in order to clear the oil life remaining percentage display. Press and hold the RESET/SELECT button for 5 seconds until the DIC acknowledges. For more information on the rest of the personalization modes, refer to Personalization Description and Operation. Outside Air Temperature The outside air temperature is read by the body control module (BCM) and transmitted over serial data to the instrument panel cluster (IPC) for display in the driver information center (DIC). The BCM provides the logic for reading the outside air temperature sensor. The BCM sends the temperature to the IPC in Celsius. The IPC is responsible for displaying the temperature and converting to Fahrenheit. Odometer The odometer information is stored in the body control module (BCM) and is transmitted to the instrument panel cluster (IPC) for display in the driver information center (DIC). The IPC stores a backup copy of the odometer value in case the IPC does not receive a valid odometer reading form the BCM. The last known good odometer value from the BCM is displayed by the IPC before ERROR is displayed in the DIC. Indicators And Warning Messages For more information on driver information center (DIC) warning messages, refer to Indicator/Warning Message Description and Operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures DRIVER INFORMATION CENTER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 16465 Driver/Vehicle Information Display: Removal and Replacement Driver Information Center Switch Replacement Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge: Customer Interest Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 16474 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy Fuel Gauge: Customer Interest Engine Controls - Fuel Gauge Inaccuracy Bulletin No.: 05-08-49-002A Date: January 28, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Fuel Gauge Accuracy and/or Fuel Gauge Fluctuation, Fuel Gauge Does Not Go To Full (Reprogram Engine Control Module (ECM)) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To January 17, 2005 Supercede: This bulletin is being updated to include the Correction information and a revised "built prior to" date. Please discard Corporate Bulletin Number 05-08-49-002 (Section 08 - Body). Condition Some customers may comment that the fuel gauge does not go to the full position when the fuel tank is full and/or that the fuel gauge has excessive fluctuating when the vehicle stops or accelerates suddenly. Correction Reprogram the ECM with a new service calibration released with TIS satellite data update version 1.75 on January 25, 2005 or newer. Refer to Service Programming System (SPS). Dealer Action Contact customers that were told they would be notified when a fix became available. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy > Page 16479 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-06-04-012A > Oct > 06 > Instruments Erratic Fuel Gauge Reading Fuel Gauge: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-06-04-012A > Oct > 06 > Instruments Erratic Fuel Gauge Reading > Page 16485 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy Fuel Gauge: All Technical Service Bulletins Engine Controls - Fuel Gauge Inaccuracy Bulletin No.: 05-08-49-002A Date: January 28, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Fuel Gauge Accuracy and/or Fuel Gauge Fluctuation, Fuel Gauge Does Not Go To Full (Reprogram Engine Control Module (ECM)) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Built Prior To January 17, 2005 Supercede: This bulletin is being updated to include the Correction information and a revised "built prior to" date. Please discard Corporate Bulletin Number 05-08-49-002 (Section 08 - Body). Condition Some customers may comment that the fuel gauge does not go to the full position when the fuel tank is full and/or that the fuel gauge has excessive fluctuating when the vehicle stops or accelerates suddenly. Correction Reprogram the ECM with a new service calibration released with TIS satellite data update version 1.75 on January 25, 2005 or newer. Refer to Service Programming System (SPS). Dealer Action Contact customers that were told they would be notified when a fix became available. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 05-08-49-002A > Jan > 05 > Engine Controls - Fuel Gauge Inaccuracy > Page 16490 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Page 16491 Fuel Gauge: Specifications FUEL LEVEL SPECIFICATIONS The information in the table is intended for use with the J 33431-C Signal Generator and Instrument Panel Tester. The fuel level sensor values represent the test values to be used on the Signal Generator to drive the fuel gage display to the indicated positions. Vehicles that require more than one fuel level sensor calculate gage position from many possible resistance combinations of fuel levels between the two tanks. Therefore, the values in the table may not correlate directly to readings taken from the vehicle primary or secondary sending units. The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Connector Views Fuel Gauge Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 16494 Fuel Gauge: Description and Operation FUEL GAGE The instrument panel cluster (IPC) displays the fuel level as determined by the powertrain control module (PCM)/engine control module (ECM). The IPC receives a GMLAN message from the body control module (BCM) indicating the fuel level volume. The fuel gage defaults to empty (E) if: - The PCM/ECM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of GMLAN communications with the BCM. When the fuel level is less than a certain low percentage, LOW FUEL message displays in the driver information center (DIC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: Customer Interest Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 16503 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-012A > Oct > 06 > Instruments Erratic Fuel Gauge Reading Fuel Gauge Sender: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-012A > Oct > 06 > Instruments Erratic Fuel Gauge Reading > Page 16509 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key Shift Interlock Switch: All Technical Service Bulletins A/T - Various Concerns With Shifter And/Or Ignition Key TECHNICAL Bulletin No.: 06-07-30-004G Date: May 27, 2010 Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined) Models: 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2006 Pontiac Pursuit (Canada Only) 2007-2010 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) Supercede: This bulletin is being revised to update the Warranty Information #4. Please discard Corporate Bulletin Number 06-07-30-004F (Section 07 - Transmission/Transaxle). Important When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts. - Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI. - Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI. - If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin. Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter binds. Cause #1 The cause of this condition may be the shifter button sticking in the handle. Correction #1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Parts Information #1 Warranty Information #1 For vehicles repaired under warranty, use: Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment they cannot remove the ignition key. Cause #2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16515 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16516 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16517 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16523 The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition. The illustration above shows the switch in a correct position. Correction #2 Important A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Parts Information #2 Warranty Information #2 For vehicles repaired under warranty, use: Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only) Some customers may comment that the shifter is hard to move. Cause #3 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16524 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction #3 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. Parts Information #3 Warranty Information #3 For vehicles repaired under warranty, use: Condition #4 (All Years, All Models) Some customers may comment that the ignition key cannot be removed from the ignition cylinder. Correction #4 Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit D1, connector (C4 or X4) at the BCM. Warranty Information #4 For vehicles repaired under warranty, use: Condition #5 (All Years, All Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 06-07-30-004G > May > 10 > A/T - Various Concerns With Shifter And/Or Ignition Key > Page 16525 Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder. Correction #5 Refer to Corporate Bulletin Number 09-02-35-005A for additional information. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16526 Fuel Pump and Sender Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16527 Fuel Gauge Sender: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fill limit vent valve - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel pump - The fuel pressure regulator - The fuel strainer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16528 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED - SA9156E Fuel Tank Lock Ring Remover - J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank. 2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer. 3. Release the fuel pump module electrical harness from the retaining slot on the tank. 4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 5. Using the SA9156E, or J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16529 6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness. 7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank. 9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container. 10. Remove and discard the fuel pump module-to-fuel tank seal (1). IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16530 1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank. 3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly. 4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16531 5. Using the SA9156E, or J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring. IMPORTANT: Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots. 6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor. 7. Secure the fuel pump module electrical harness into the retaining slot on the tank. 8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer. 9. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16537 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16538 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16539 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16540 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16541 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16542 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16543 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16544 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16545 Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling Zones SIR DISABLING AND ENABLING ZONES IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone, depending on the location of other SIR components, and the area being serviced. Refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. SIR Disabling and Enabling Zone 1 SIR DISABLING AND ENABLING ZONE 1 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16546 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Open front hood, and locate the front end sensor also known as the electronic frontal sensor (EFS) (2). 7. Remove the connector position assurance (CPA) from the front end sensor connector. 8. Remove the front end sensor connector from the front end sensor (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the front end sensor connector to the front end sensor (2). 3. Connect the CPA to the front end sensor connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16547 4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 5. Install the BCM fuse center cover. 6. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 7. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 2 SIR DISABLING AND ENABLING ZONE 2 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16548 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-right go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector. 9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-right connector. 12. Disconnect the roof rail module-right connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16549 13. Remove the RH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-right. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-right. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 10. 3. Install the SIS-right connector to the SIS-right. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the RH door trim panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16550 7. Connect the roof rail module-right connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-right connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. 11. Install the lower center pillar. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16551 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 3 SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16552 deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the left/driver outer trim cover from the instrument panel (I/P). 7. Remove the connector position assurance (CPA) from the steering wheel module coil connector. 8. Disconnect the steering wheel module coil connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the steering wheel module coil connector to the vehicle harness connector. 3. Install the CPA to the steering wheel module coil connector. 4. Install the left outer trim cover to the I/P. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16553 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 5 SIR DISABLING AND ENABLING ZONE 5 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove the fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16554 center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the right/passenger outer trim cover from the instrument panel (I/P) (3). 7. Remove the connector position assurance (CPA) from the I/P module connector (2). 8. Disconnect the I/P module connector (1) from the vehicle harness connector (2). ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the I/P module connector (1) to the vehicle harness connector (2). 3. Install the CPA to the I/P module connector (2). 4. Install the right outer trim cover to the I/P (3). 5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 6. Install the BCM fuse center cover. 7. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 8. Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 6 SIR DISABLING AND ENABLING ZONE 6 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16555 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center, then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has 2 fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-left go to step 13. 7. Remove the lower center pillar trim. 8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector. 9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16556 10. Remove the garnish molding from the upper lock pillar. 11. Remove the CPA from the roof rail module-left connector. 12. Disconnect the roof rail module-left connector from the vehicle harness connector. 13. Remove the LH door trim panel. 14. Peel back the door water deflector far enough to access the SIS-left. 15. Remove the CPA from the SIS connector. 16. Disconnect the SIS connector from the SIS-left. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. To enable the SIS-left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 10. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16557 3. Install the SIS-left connector to the SIS-left. 4. Install the CPA to the SIS connector. 5. Reinstall door water deflector. 6. Install the LH door trim panel. 7. Connect the roof rail module-left connector to the vehicle harness connector. 8. Install the CPA to the roof rail module-left connector. 9. Install the garnish molding to the upper lock pillar. 10. Connect the seat belt pretensioner-LF and install the CPA. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16558 11. Install the lower center pillar. 12. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 13. Install the BCM fuse center cover. 14. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash, then turn OFF. 15. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. SIR Disabling and Enabling Zone 8 SIR DISABLING AND ENABLING ZONE 8 DISABLING PROCEDURE 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Locate the body control module (BCM) fuse center then remove fuse center cover. 5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16559 IMPORTANT: This inflatable restraint sensing and diagnostic module (SDM) has two fused power inputs. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove both AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center. With the AIR BAG fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the garnish molding from the right upper lock pillar. 7. Remove the connector position assurance (CPA) from the roof rail module-right connector. 8. Disconnect the roof rail module-right connector from the vehicle harness connector. 9. Remove the lower right center pillar trim. 10. Remove the CPA from seat belt pretensioner-RF connector. 11. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector. 12. Remove the passenger/right outer trim cover from the instrument panel (I/P) (3). 13. Remove the CPA from the I/P module connector (1). 14. Disconnect the I/P module connector (1) from the vehicle harness connector (2). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16560 15. Remove the driver/left outer trim cover from the I/P. 16. Remove the CPA from the steering wheel module coil connector. 17. Disconnect the steering wheel module coil connector from the vehicle harness connector. 18. Remove the lower left center pillar trim. 19. Remove the CPA from seat belt pretensioner-LF connector. 20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector. 21. Remove the garnish molding from the upper lock pillar. 22. Remove the CPA from the roof rail module-left connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16561 23. Disconnect the roof rail module-left connector from the vehicle harness connector. ENABLING PROCEDURE 1. Remove the key from the ignition switch. 2. Connect the roof rail module-left connector to the vehicle harness connector. 3. Install the CPA to the roof rail module-left connector. 4. Install the garnish molding to the left upper lock pillar. 5. Connect the seat belt pretensioner-LF connector. 6. Install the CPA to the seat belt pretensioner-LF connector. 7. Install the left/driver lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16562 8. Connect the steering wheel module coil connector to the vehicle harness connector. 9. Install the CPA to the steering wheel module coil connector. 10. Install the driver/left outer trim cover to the I/P. 11. Connect the I/P module connector (1) to the vehicle harness connector (2). 12. Install the CPA to the I/P module connector (1). 13. Install the passenger/right outer trim cover to the I/P (3). 14. Connect the seat belt pretensioner-RF connector. 15. Install the CPA to the seat belt pretensioner-RF connector. 16. Install the right lower center pillar trim. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > SIR Disabling and Enabling Zones > Page 16563 17. Connect the roof rail module-right connector to the vehicle harness connector. 18. Install the CPA to the roof rail module-right connector. 19. Install the garnish molding to the right upper lock pillar. 20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center. 21. Install the BCM fuse center cover. 22. Use caution while reaching in and turn the ignition switch to the ON position.The AIR BAG indicator will flash then turn OFF. 23. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: Customer Interest Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: All Technical Service Bulletins Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied directly to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the diagnostic. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1 - 6 The number below refers to the step number on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 16590 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE CIRCUIT DESCRIPTION The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). Ignition voltage is supplied to the MIL. The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL Function The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. - The MIL illuminates during a bulb test and a system test. - A DTC will be stored if a MIL is requested by the PCM. MIL Illumination The MIL will illuminate with the ignition switch ON and the engine OFF. - The MIL will turn OFF when the engine is started. - The MIL will remain ON if the self-diagnostic system has detected a malfunction. - The MIL may turn OFF if the malfunction is not present. - If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. - If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 16591 Steps 1 - 11 The number below refers to the step number on the diagnostic table. 3. This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be no voltage on the MIL control circuit. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16596 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16597 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16598 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 16599 Odometer: Description and Operation ODOMETER The vehicle odometer is calculated and stored electronically in the body control module (BCM) and is sent via GMLAN to the instrument panel cluster (IPC) for display. The BCM calculates and stores the mileage based on the vehicle speed GMLAN message from the powertrain control module (PCM)/engine control module (ECM). The IPC displays the season odometer information from the BCM in the driver information center (DIC). The odometer will display error if the IPC detects an invalid odometer data from the BCM. After an invalid odometer data is received from the BCM, the IPC will display the last known odometer reading for 1.5 seconds before error is displayed in the DIC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation ENGINE OIL LIFE SYSTEM WHEN TO CHANGE ENGINE OIL Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A "CHANGE OIL SOON" message in the Driver Information Center (DIC) will come on. Change your oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 16603 Oil Change Reminder Lamp: Service and Repair ENGINE OIL LIFE SYSTEM HOW TO RESET THE ENGINE OIL LIFE SYSTEM The Engine Oil Life System calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a CHANGE OIL SOON message being turned on, reset the system. After changing the engine oil, the system must be reset as follows: 1. Turn the ignition to "RUN", with the engine off. 2. Press the "information" and "reset" buttons on the DIC at the same time to enter the personalization menu. 3. Press the "information" button to scroll through the available personalization menu modes until the DIC display shows "OIL-LIFE RESET". 4. Press and hold the "reset" button until the DIC display shows "ACKNOWLEDGED". This will tell you the system has been reset. 5. Turn the key to "LOCK". If the CHANGE OIL SOON message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the reset procedure. WHAT TO DO WITH USED OIL Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 16611 Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 16615 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 16616 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: Customer Interest Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: Customer Interest Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-49-019 > Jun > 05 > Instruments - Intermittent Brake Warning Lamp Instrument Panel Control Module: All Technical Service Bulletins Instruments - Intermittent Brake Warning Lamp Bulletin No.: 05-08-49-019 Date: June 22, 2005 TECHNICAL Subject: Brake System Warning Light Comes On Intermittently (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the brake system warning light comes on intermittently. The brake light will illuminate for 2 to 3 seconds, then will turn off and may never illuminate again. The vehicle should exhibit no braking concerns at all. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Inspect the brake fluid level and the operation of the parking brake signal switch. If normal, technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. The customer should be thoroughly questioned to determine if a warning chime accompanies the brake system warning light, and if the BRAKE FLUID or PARKING BRAKE messages are displayed on the DIC when the condition occurs. The condition being discussed does not include any DIC message or warning chime. If the customer reports hearing the warning chime or the DIC messages, then further diagnosis is needed, searching for unwanted inputs from the parking brake switch signal or brake fluid switch signal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-49-020 > Jun > 05 > Instruments - Gauges Inoperative/Speedo Offset From Zero Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges Inoperative/Speedo Offset From Zero Bulletin No.: 05-08-49-020 Date: June 23, 2005 TECHNICAL Subject: Instrument Panel Cluster (IPC) Gauges Inoperative - Speedometer Off set From Zero, Erratic Tachometer, Fuel Gauge Erratic (Reprogram IPC) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment that the instrument panel gauges appear to lose their position or are inoperative. Cause A software anomaly within the IPC has been found. If battery voltage drops as a result of a slow drain, the IPC will reset. Upon exiting reset, the IPC will move the speedometer pointer by 10 degrees. Each time the IPC resets, the speedometer pointer will move an additional 10 degrees. The speedometer will off set between 10 to 340 degrees total. Once the battery voltage begins to rise, the fuel and tachometer pointers will move up by 10 degrees. Correction Important: Programming the IPC must be done PASS-THRU ONLY. Technicians are to reprogram the IPC with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Clutch Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16644 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16650 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 16655 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 16656 I/P Dimmer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 16657 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 16661 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 16662 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 16663 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: Customer Interest Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 16672 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading Fuel Gauge Sender: All Technical Service Bulletins Instruments - Erratic Fuel Gauge Reading Bulletin No.: 06-06-04-012A Date: October 31, 2006 TECHNICAL Subject: Erratic Fuel Gage Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) Models: 2006 Chevrolet Cobalt 2006 Pontiac Pursuit (Canada Only) Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac) Supercede: This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine). Condition Some customers may comment on erratic fuel gage readings. A typical comment might be that the gage does not go to full or moves off full too quickly. Cause This condition may be caused by an improperly calibrated fuel level sensor. Correction Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-06-04-012A > Oct > 06 > Instruments - Erratic Fuel Gauge Reading > Page 16678 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16679 Fuel Pump and Sender Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16680 Fuel Gauge Sender: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fill limit vent valve - The fuel level sensor - The fuel tank pressure (FTP) sensor - The fuel pump - The fuel pressure regulator - The fuel strainer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16681 Fuel Gauge Sender: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED - SA9156E Fuel Tank Lock Ring Remover - J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank. 2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer. 3. Release the fuel pump module electrical harness from the retaining slot on the tank. 4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor. 5. Using the SA9156E, or J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16682 6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness. 7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank. 9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container. 10. Remove and discard the fuel pump module-to-fuel tank seal (1). IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16683 1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank. 3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly. 4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16684 5. Using the SA9156E, or J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring. IMPORTANT: Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots. 6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor. 7. Secure the fuel pump module electrical harness into the retaining slot on the tank. 8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank. IMPORTANT: Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer. 9. Install the fuel tank. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 16688 Ambient Air Temperature Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Floor Panel Components and Grounds Floor Panel Components and Grounds 1 - Floor Shift Light 2 - Floor Pan 3 - A/T Shift Lock Control Solenoid (MN5) 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 5 - G306 6 - Park Brake Switch 7 - G301 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 16692 Park Brake Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 16693 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front floor console upper trim plate. 2. Disconnect the warning lamp switch electrical connector (2). 3. Remove the warning lamp switch mounting screw (1). 4. Remove the switch from the park brake lever assembly. Installation Procedure 1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever assembly. 2. Install the switch to the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting screw (1). ^ Tighten the screw to 3 Nm (27 inch lbs.). 4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor console upper trim plate. 6. Verify correct park brake warning lamp operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The instrument panel cluster (IPC) displays the vehicle speed based on GMLAN serial data message from the body control module (BCM). The BCM receives vehicle speed data from the powertrain control module (PCM)/engine control module (ECM) via the GMLAN serial data circuit. The speedometer will default to 0 km/h (0 mph) if: - The PCM/ECM detects a malfunction in the vehicle speed sensor circuit. - The BCM detects a loss of GMLAN communications with the PCM/ECM. - The IPC detects a loss of GMLAN communications with the BCM. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The instrument panel cluster (IPC) displays the engine speed as determined by the powertrain control module (PCM)/engine control module (ECM). The IPC receives a GMLAN message from the body control module (BCM) indicating the engine speed. The tachometer will default to 0 RPM if: - The PCM detects a malfunction in the engine speed sensor circuit. - The BCM detects a loss of GMLAN communications with the PCM/ECM. - The IPC detects a loss of GMLAN communications with the BCM. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 16713 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Page 16718 Transmission Shift Position Indicator Lamp: Service and Repair TRANS FLOOR SHIFT CONTROL INDICATOR LAMP REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16723 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16724 Ambient Light Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16725 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Transmission Components (MPG) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) Backup Light Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (COUPE) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16734 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16735 Backup Light Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Sedan) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (SEDAN) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16736 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) Brake Light Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (COUPE) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16742 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16743 Brake Light Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Sedan) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (SEDAN) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16744 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16753 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16759 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16760 Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16761 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16762 Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16763 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16764 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. With the brake pedal fully released, insert the stop lamp switch into the brake pedal bracket until the switch plunge is fully depressed into the barrel. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 3. Twist the switch clockwise until the travel stop has been reached. 4. The plunger should extend out of the barrel (1) of the switch approximately 1.0 mm (0.04 in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16765 5. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in) 6. Inspect the stop lamps for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16766 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. Remove the stop lamp switch by grasping the switch and turning it counterclockwise while pulling toward the front of the vehicle. 3. Disconnect the stop lamp switch electrical connector. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16767 1. Connect the stop lamp switch electrical connector. 2. Insert the stop lamp switch into the retainer. 3. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in). 4. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair Cargo Lamp: Service and Repair CARGO LAMP REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp (CHMSL) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 16774 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Description and Operation Courtesy Lamp: Description and Operation COURTESY/ILLUMINATED ENTRY LAMPS This group includes lamps that may be manually turned ON by placing the interior lamp switch in the ON position, or by opening a door. - The dome lamp - The reading lamps - The rearview mirror lamps - The vanity mirror lamps The dome lamp switch has 3 positions: DOOR, OFF, and ON. When in the DOOR position, the dome lamp operation is controlled by the body control module (BCM). The ON position provides a ground for continuous operation. Ground is provided at G302. The OFF position turns OFF any dome lamp operation. The courtesy lamps, may be manually turned ON by placing the instrument panel (I/P) dimmer switch in the DOME position. When the dome lamp switch is in the DOOR position, the dome lamp will illuminate when a door is opened. When a door is opened, the courtesy lamps turn ON. After all the doors have been closed, the courtesy lamps will remain illuminated approximately 10 seconds after the last door closes. When the driver places the dome lamp switch in the OFF position, the dome lamp will be disabled. The inadvertent power control circuit of the BCM supplies battery positive voltage to the dome lamp, reading lamps, and vanity mirror lamps. When any door is opened, the door jam switch contacts close and the door open input to the BCM is grounded. If the driver inadvertently leaves any interior lamp ON, the BCM will turn it OFF after 20 minutes. The courtesy lamps will normally turn OFF using the theater dimming feature. The BCM provides a pulse width modulated ground to the dome lamp for the theater dimming feature. The courtesy lamps will also turn OFF immediately if a door lock command is received with all the doors closed, or if the ignition switch is turned to the ON position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views Daytime Running Lamp: Connector Views Park /Turn Signal DRL Lamp - LF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views > Page 16782 Park / Turn Signal DRL Lamp - RF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page 16783 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The ambient light sensor is a light sensitive transistor that varies its voltage signal to the body control module (BCM) in response to changes to the outside (ambient) light level. When the BCM receives this signal, it will either turn ON the daytime running lamps (DRL) or the headlights if the headlamp switch is in the AUTO position. Any function or condition that turns ON the headlights will cancel the DRL operation. With the headlight switch in the AUTO position, the headlights will either be turned ON or OFF, after an approximate 30-second delay depending on whether daylight or low light conditions are sensed. The DRL illuminates the park/turn signal and DRL lamps. The DRL will operate when the ignition switch is in the ON position, the gear selector is not in the PARK position, and the parking brake is released. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. DRL operation in manual transmission equipped vehicles will occur when the ignition switch is in the ON position, and the parking brake is released. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16787 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16788 I/P Dimmer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16789 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair DOME LAMP BULB REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16797 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16798 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16799 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 16804 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 16805 Fog Lamp Switch (With RPO Code T37) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 16806 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 16811 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 16812 Hazard Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 16813 Hazard Warning Switch: Service and Repair HAZARD WARNING SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 16814 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 16832 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments Backlighting Inoperative During Daylight Interior Lighting Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments Backlighting Inoperative During Daylight > Page 16838 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Lamp Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 16843 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the license plate from the rear bumper fascia. 2. Remove the screws (1) from the license plate lamp. 3. Remove the license plate lamp (2) from the rear bumper fascia. 4. Remove the bulb/socket from the license plate lamp (2) by turning counterclockwise. 5. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Install the socket to the license plate lamp (2) by turning the socket clockwise. 3. Install the license plate lamp (2) to the rear bumper fascia. 4. Install the screws (1) to the license plate lamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the license plate lamp screws to 2 N.m (18 lb in). 5. Install the license plate to the rear bumper fascia. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair READING LAMP BULB REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) Marker Lamp Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (COUPE) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16853 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16854 Marker Lamp Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Sedan) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (SEDAN) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16855 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16860 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views Parking Lamp: Connector Views Park /Turn Signal DRL Lamp - LF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 16863 Park / Turn Signal DRL Lamp - RF Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 16864 Parking Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail, and marker lamps, including the license lamps, are turned ON when the headlamp switch is placed in the PARK or HEADLAMP position, or anytime the headlights are requested. The PARK LAMPS fuse in the rear fuse block supplies battery positive voltage to the PARK LAMP relay switch contacts. The PARK LAMPS fuse in the rear fuse block also supplies battery positive voltage to the PARK LAMP relay coil. When the park lamps are turned ON, the body control module (BCM) energizes the park lamp relay. Current flow is from the PARK LAMP relay to their respective park and marker lamps and to ground. Ground is provided at G101, G102, G401, and G403. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: Customer Interest Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 16874 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight Interior Lighting Module: All Technical Service Bulletins Instruments - Backlighting Inoperative During Daylight Bulletin No.: 06-08-49-016B Date: September 12, 2006 TECHNICAL Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) Models: 2004-2006 Chevrolet Malibu, Malibu Maxx 2005-2006 Chevrolet Cobalt 2006 Chevrolet HHR 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Solstice 2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344 Supercede: This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 - Body & Accessories). Condition Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time. Cause On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer's personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on. Correction Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list. For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Interior Lighting Module: > 06-08-49-016B > Sep > 06 > Instruments - Backlighting Inoperative During Daylight > Page 16880 Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16885 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16886 Ambient Light Sensor Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16887 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Components (MPG) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: Customer Interest Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16899 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition Brake Light Switch: All Technical Service Bulletins Electrical - Cruise Control Inop/No Start Condition Bulletin No.: 06-08-68-002 Date: July 18, 2006 TECHNICAL Subject: Cruise Control Inoperative, Vehicle May Not Start When Clutch Pedal Is Engaged, Brake (Stop) Lamps May Not Function Properly (Remove Foam From Pedals and Replace Affected Switches) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) 2005 Saturn ION Built Up To and Including the VIN Breakpoints shown. Condition Some customers may comment on any of the following conditions: ^ The cruise control is inoperative. ^ The vehicle may not start when the clutch pedal is engaged. ^ The brake (stop) lamps may not function properly. Cause These conditions may be caused by worn foam in the clutch or brake pedal that results in the cruise release switch, the clutch pedal engine start switch (if equipped), or stop lamp switch being out of adjustment. Correction Remove the foam from the contact areas on both the clutch pedal (if equipped) and the brake pedal. Replace the cruise release switch, the stop lamp switch and the clutch pedal engine start switch (if equipped). 1. Verify the customer concern. 2. Remove foam from the contact areas on the brake pedal and the clutch pedal (if equipped). Use a putty knife or razor to remove the foam, then wipe the pedal(s) with isopropyl alcohol until all adhesive residue has been removed. Important: After replacing the switches, be sure to perform the required adjustment procedures referenced in SI. 3. Replace the cruise release switch. Refer to Cruise Release Switch Replacement in SI. 4. Replace the stop lamp switch. Refer to Stop Lamp Switch Replacement in SI. 5. Replace clutch pedal engine start switch (if equipped). Refer to Clutch Pedal Engine Start Switch Replacement in SI. 6. Verify that the customer concern has been corrected. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 06-08-68-002 > Jul > 06 > Electrical - Cruise Control Inop/No Start Condition > Page 16905 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16906 Pedal Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16907 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16908 Stop Lamp Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16909 Stop Lamp/TCC Switch (K34 With RPO Code M86 Or MU3) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16910 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. With the brake pedal fully released, insert the stop lamp switch into the brake pedal bracket until the switch plunge is fully depressed into the barrel. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 3. Twist the switch clockwise until the travel stop has been reached. 4. The plunger should extend out of the barrel (1) of the switch approximately 1.0 mm (0.04 in). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16911 5. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in) 6. Inspect the stop lamps for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16912 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the accelerator pedal retaining nuts. Move the pedal aside. 2. Remove the stop lamp switch by grasping the switch and turning it counterclockwise while pulling toward the front of the vehicle. 3. Disconnect the stop lamp switch electrical connector. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 16913 1. Connect the stop lamp switch electrical connector. 2. Insert the stop lamp switch into the retainer. 3. Install the accelerator pedal to the dash panel. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in). 4. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 16917 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Door Jamb Switch - Driver Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16921 Door Jamb Switch - LR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16922 Door Jamb Switch - Passenger Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16923 Door Jamb Switch - RR (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16927 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16928 Fog Lamp Switch (With RPO Code T37) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16929 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 16933 I/P Components Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 16934 Hazard Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 16935 Hazard Warning Switch: Service and Repair HAZARD WARNING SWITCH REPLACEMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 16936 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Power Steering System Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16943 Turn Signal Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16944 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16945 Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Removal Procedure 1. Remove the steering column trim covers. 2. Disconnect the multifunction turn signal switch harness connector. 3. Depress the locking tabs and remove the multifunction turn signal switch from the steering column. Installation Procedure 1. Install the multifunction turn signal switch to the steering column. Ensure the locking tabs are snapped into place. 2. Connect the multifunction turn signal switch harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16946 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16951 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Tail/Stop and Turn Signal Lamp - Left (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 16954 Tail/Stop and Turn Signal Lamp - Right (Coupe) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 16955 Tail/Stop and Turn Signal Lamp - Left (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 16956 Tail/Stop and Turn Signal Lamp - Right (Sedan) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16957 Tail Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail, and marker lamps, including the license lamps, are turned ON when the headlamp switch is placed in the PARK or HEADLAMP position, or anytime the headlights are requested. The PARK LAMPS fuse in the rear fuse block supplies battery positive voltage to the PARK LAMP relay switch contacts. The PARK LAMPS fuse in the rear fuse block also supplies battery positive voltage to the PARK LAMP relay coil. When the park lamps are turned ON, the body control module (BCM) energizes the park lamp relay. Current flow is from the PARK LAMP relay to their respective park and marker lamps and to ground. Ground is provided at G101, G102, G401, and G403. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) Tail Lamp: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (COUPE) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16960 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16961 Tail Lamp: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Sedan) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (SEDAN) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16962 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation Trunk Lamp: Description and Operation REAR COMPARTMENT LAMP The inadvertent power relay also provides battery positive voltage to the rear compartment lamp. When the rear compartment is opened, its switch closes to provide a ground circuit and the rear compartment lamp illuminates. Ground is provided at G401. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Page 16970 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) Turn Signal Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (COUPE) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16976 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16977 Turn Signal Bulb: Service and Repair Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Sedan) TAIL LAMP ASSEMBLY AND /OR BACKUP, SIDEMARKER, STOP, TURN SIGNAL BULB REPLACEMENT (SEDAN) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement (Coupe) > Page 16978 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Power Steering System Component Views Steering Wheel and Column Steering Wheel and Column 1 - Turn Signal/Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper/Washer Switch 4 - Steering Wheel 5 - Steering Wheel Controls - Right (UK3) 6 Horn Switch 7 - Steering Wheel Controls - Left (UK3) 8 - Electronic Power Steering Control Module (EPS) 9 - Electronic Power Steering (EPS) Control Motor 10 - Ignition Switch 11 - Ignition Lock Cylinder Control Solenoid (MN5) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16982 Turn Signal Switch: Diagrams Turn Signal/Multifunction Switch C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16983 Turn Signal/Multifunction Switch C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16984 Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Removal Procedure 1. Remove the steering column trim covers. 2. Disconnect the multifunction turn signal switch harness connector. 3. Depress the locking tabs and remove the multifunction turn signal switch from the steering column. Installation Procedure 1. Install the multifunction turn signal switch to the steering column. Ensure the locking tabs are snapped into place. 2. Connect the multifunction turn signal switch harness connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16985 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16995 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16996 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16997 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17003 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17004 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17005 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heated Glass Element: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise Window Frame: All Technical Service Bulletins Body - Rear Door Wind Noise Bulletin No.: 05-08-58-004 Date: August 22, 2005 TECHNICAL Subject: Rear Door Wind Noise (Apply Sealer) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment on wind noise coming from the rear door stationary glass. Cause This condition may be caused by the rubber seal surrounding the stationary glass not making contact to the door frame. Correction 1. Remove the rear door stationary door glass following SI Document ID 1549117. 2. Apply 5 mm (1/4 in) bead of 3M(R) Bedding & Glazing Compound around the center of the stationary door glass frame. 3. When reinstalling the stationary glass, there is a metal tang at the top of the division post. Pull the vent glass down and rearward until you hear this metal tang seat into the square hole in the door frame. Refer to the arrow in the illustration above. 4. Reinstall the door trim following SI Document ID 1549117. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heated Glass Element: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise > Page 17011 Parts Information Warranty Information For vehicles repaired under warranty, use table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heated Glass Element: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise > Page 17017 Parts Information Warranty Information For vehicles repaired under warranty, use table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17020 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17021 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17022 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17023 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17024 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17025 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17026 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17027 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17028 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17029 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17030 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17031 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17032 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17033 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17034 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17035 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17036 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17037 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17038 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17039 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17040 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17041 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17042 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17043 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17044 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17045 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17046 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17047 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17048 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17049 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17050 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17051 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17052 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17053 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17054 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17055 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17056 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17057 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17058 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17059 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17060 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17061 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17062 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17063 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17064 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17065 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17066 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17067 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17068 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17069 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17070 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17071 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17072 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17073 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17074 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17075 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17076 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17077 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17078 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17079 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17080 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17081 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17082 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17083 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17084 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17085 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17086 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17087 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17088 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17089 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17090 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17091 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17092 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17093 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17094 Heated Glass Element: Connector Views Rear Window Defogger Grid C1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 17095 Rear Window Defogger Grid C2 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 17096 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: The HVAC control assembly - The body control module (BCM) - The REAR DEFOG relay - The rear window grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied through the RR DEFOG fuse, in the underhood fuse block, to the REAR DEFOG relay switched input. Ground for the REAR DEFOG relay is provided by G101. The BCM supplies 12 volts on the rear window defogger switch signal circuit to the HVAC control assembly. When you depress the rear window defogger switch, the rear window defogger switch pulls the signal circuit low. The BCM interprets as a request for the rear window defogger system. The BCM enables the rear window defogger system by supplying voltage to the REAR DEFOG relay coil. The relay coil supply voltage is also spliced off internally in the BCM to the supply voltage circuit of the rear window defogger indicator. The REAR DEFOG relay is energized and the rear window defogger indicator is illuminated. With the relay energized, battery positive voltage is allowed from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger grid. Ground for the rear window defogger grid is provided by G403. When you start the engine and press the rear window defogger switch for the first time, the defogger cycle lasts for 15 minutes. Further operation results in 7.5 minute defogger cycles. The defogger cycle resets to 15 minutes when you cycle the ignition to the OFF position and then to the ON position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT For the inside rearview mirror with the automatic day-night feature, begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Diagnostic System Check Vehicle, in order to identify the correct procedure for diagnosing the system and where the procedure is located. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Vehicle. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17099 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: - For the inside rearview mirror with the automatic day-night feature, review the system operation in order to familiarize yourself with the system functions. Refer to Automatic Day-Night Mirror Description and Operation. - For the rear window defogger system, the following steps must be performed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle, before using the symptom tables in order to verify that all of the following are true: Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle - There are no DTCs set. - The control modules can communicate via the serial data link. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the rear window defogger system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Indicator Always On - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative Automatic Day/Night Mirror Inoperative - Mirrors MIRRORS - AUTOMATIC DAY-NIGHT INOPERATIVE DIAGNOSTIC AIDS The automatic day-night feature of the inside rearview mirror may not operate properly or become inoperative due to an intermittent short to battery positive voltage in the backup lighting system. TEST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17100 Steps 1 - 10 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17101 Steps 11 - 12 Defogger Indicator Always On - Stationary Windows DEFOGGER INDICATOR ALWAYS ON TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17102 Steps 1 - 12 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17103 Step 13 The number below refers to the step number on the diagnostic table. 3. Command both the ON and OFF states of the rear window defogger switch. Repeat the command as necessary to verify the Rear Defog Switch Input data parameter does or doesn't change states. Defogger Inoperative - Rear Window DEFOGGER INOPERATIVE - REAR WINDOW TEST DESCRIPTION Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17104 Steps 1 - 9 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17105 Steps 10 - 21 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17106 Steps 22 - 27 The number below refers to the step number on the diagnostic table. 8. Listen for an audible click when the relay operates. Command both the ON and OFF states of the REAR DEFOG relay. Repeat the commands as necessary. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17107 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS IMPORTANT: This test is for reference only. A grid line fault requires rear window replacement. Refer to Rear Window Replacement. 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 5. Once the open (2) is located, replace the rear window. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 17108 Heated Glass Element: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS BODY CONTROL MODULE (BCM) A/C Switch: The scan tool displays On or Off. The BCM displays On when it receives an input from the HVAC control head indicator an A/C request. Battery 1: The scan tool displays the value of the vehicle battery voltage. Rear Defog Relay: The scan tool displays On or Off. When the BCM energizes the Rear Defogger relay, the scan tool will display On. When the BCM de-energizes the Rear Defogger relay, the scan tool will display Off. Rear Defog Switch Input: The scan tool displays On or Off. When you depress the rear window defogger switch, the switch pulls the rear defogger switch signal circuit of the BCM low. The scan tool will display On. When you depress the switch again, the rear defogger switch signal circuit of the BCM will return to its normal state. The scan tool will display Off. Body Control Module (BCM) Body Control Module (BCM) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 17113 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17116 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17117 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17118 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17119 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17120 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17121 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17122 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17123 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17124 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17125 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17126 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17127 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17128 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17129 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17130 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17131 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17132 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17133 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17134 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17135 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17136 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17137 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17138 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17139 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17140 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17141 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17142 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17143 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17144 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17145 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17146 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17147 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17148 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17149 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17150 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17151 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17152 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17153 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17154 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17155 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17156 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17157 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17158 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17159 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17160 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17161 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17162 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17163 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17164 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17165 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17166 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17167 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17168 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17169 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17170 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17171 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17172 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17173 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17174 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17175 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17176 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17177 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17178 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17179 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17180 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17181 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17182 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17183 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17184 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17185 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17186 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17187 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17188 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 17189 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17195 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17196 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17197 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17198 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17199 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17200 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17201 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17202 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17203 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17204 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17205 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17206 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17207 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17208 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17209 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17210 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17211 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17212 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17213 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17214 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17215 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17216 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17217 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17218 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17219 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17220 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17221 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17222 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17223 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17224 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17225 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17226 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17227 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17228 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17229 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17230 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17231 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17232 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17233 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17234 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17235 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17236 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17237 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17238 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17239 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17240 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17241 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17242 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17243 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17244 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17245 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17246 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17247 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17248 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17249 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17250 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17251 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17252 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17253 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17254 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17255 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17256 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17257 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17258 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17259 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17260 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17261 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17262 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17263 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17264 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17265 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17266 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17267 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17268 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17269 Power Window Switch: Connector Views Window Switch - Driver (Coupe) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17270 Window Switch - Driver C1 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17271 Window Switch - Driver C2 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17272 Window Switch - RR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17273 Window Switch - Passenger (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17274 Window Switch - LR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front Power Window Switch: Service and Repair Power Window Switch Replacement - Left Front Power Window Switch Replacement - Left Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 17277 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 17278 Power Window Switch: Service and Repair Power Window Switch Replacement - Right Front Power Window Switch Replacement - Right Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17288 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17289 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17290 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17291 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17292 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17293 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17294 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17295 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17296 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS INDUCING INTERMITTENT FAULT CONDITIONS Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17297 There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. - Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. - An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17298 NOTE: Refer to Test Probe Note in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17299 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE TOOLS REQUIRED J 42598 Vehicle Data Recorder Snapshot is a recording of the parameters of a control module while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition recur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. There are many different scan tools that have varying functions. For example, the Tech 2 Scan Tool can also graph parameters separately or in combinations of parameters for comparison. Only a single data list may be recorded in each snapshot. It can trigger a Snapshot manually at the time the symptom is noticed, or be set up in advance to trigger when a DTC sets. The Tech 2 Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: Snapshot-taken from the Snapshot menu choice - Quick Snapshot-taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1,200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Tech 2 Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. VEHICLE DATA RECORDER Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17300 The J 42598 is connected to the data link connector (DLC) and sent with the customer. The J 42598 captures data for later retrieval and analysis by the technician. Refer to the vehicle data recorder user instructions for more information. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17301 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent Conditions and Poor Connections TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS TOOLS REQUIRED - J 35616 GM-Approved Terminal Test Kit - J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. - Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. - Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. - Wiring that comes in contact with hot or exhaust components - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. TESTING FOR PROPER TERMINAL CONTACT It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. ROUND WIRE CONNECTORS Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. CONTROL MODULE/COMPONENT VOLTAGE AND GROUNDS Poor voltage or ground connections can cause widely varying symptoms. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17302 - Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Power Distribution Schematics. - Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing and Ground Distribution Schematics. TEMPERATURE SENSITIVITY - An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. - Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. - If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. - If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. - Information from the customer may help to determine if the trouble follows a pattern that is temperature related. - If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. ELECTROMAGNETIC INTERFERENCE (EMI) AND ELECTRICAL NOISE Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. - Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. - Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. - Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. - The generator may be allowing AC noise into the electrical system. INCORRECT CONTROL MODULE - There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. IMPORTANT: :DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. - Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References in Computer/Integrating Systems for replacement, setup, and programming. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17303 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified Pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED J 35616-200 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17304 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: - Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. - When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Bosch Connectors (BSK) BOSCH CONNECTORS (BSK) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17305 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (0.64) BOSCH CONNECTORS (0.64) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17306 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17307 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. TERMINAL REPLACEMENT PROCEDURE 1. Never insert the same terminal back into the connector once it is removed. Crimp on a new terminal. 2. Prior to installation the terminal must be aligned so the coding lugs align with the coding grooves on the connector. 3. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 4. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 5. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) BOSCH CONNECTORS (2.8 JPT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17308 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Delphi Connectors (Weather Pack) DELPHI CONNECTORS (WEATHER PACK) TOOLS REQUIRED J-38125Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17309 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (Push To Seat) DELPHI CONNECTORS (PUSH TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17310 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull To Seat) DELPHI CONNECTORS (PULL TO SEAT) TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro-Pack 100W) DELPHI CONNECTORS (MICRO-PACK 100W) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17311 TOOLS REQUIRED J-38125 Terminal Repair Kit TERMINAL REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17312 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17313 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17314 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. TERMINAL REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17315 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Micro .64) DELPHI CONNECTORS (MICRO.64) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17316 IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17317 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Tyco/AMP Connectors (CM 42-Way) TYCO/AMP CONNECTORS (CM 42-WAY) TOOLS REQUIRED J-38125 Terminal Repair Kit REMOVAL PROCEDURE 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17318 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17319 TERMINAL REPAIR PROCEDURE Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used.Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal.For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings.For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Tyco/AMP Connectors (Sensor) TYCO/AMP CONNECTORS (SENSOR) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17320 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (025 Cap) TYCO/AMP CONNECTORS (025 CAP) TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17321 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. IMPORTANT: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17322 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yakazi Connectors YAKAZI CONNECTORS TOOLS REQUIRED J-38125Terminal Repair Kit TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component. 2. Insert a small flat blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17323 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. TERMINAL REPAIR PROCEDURE Use the appropriate terminal and follow the instructions in the J-38125. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17324 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN WIRING REPAIRS TOOLS REQUIRED Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17325 J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: Duraseal splice sleeves - A wire stripping tool - J 38125-8 (12085115) crimping tool - J 38125-5 (12085116) ultratorch The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors GMLAN REPAIRS IMPORTANT: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN CONNECTOR TERMINAL REPAIR IMPORTANT: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. GMLAN WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except coaxial. - Do not use the duraseal splice sleeve to form a splice with more than 2 wires coming together. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17326 IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17327 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs HIGH TEMPERATURE WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit HIGH TEMPERATURE WIRING Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. - Replace any heat shielding that is removed. - Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). - After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. IDENTIFYING HIGH TEMPERATURE WIRING Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17328 - Duraseal splice sleeves to crimp and seal connections - High temperature SCT1 shrink tubing to protect the splice sleeves - A large sampling of common electrical terminals - The correct crimp tool to attach the terminals to the wires - The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. HIGH TEMPERATURE WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape. IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17329 7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool. 8. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 9. Insert the wire into the duraseal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17330 13. Center the high temperature SCT1 shrink tube over the duraseal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17331 The tool kit J-38125 contains the following items: Duraseal splice sleeves-In order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The duraseal splice sleeves have the following 2 critical features: A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS WIRE PIGTAIL REPAIR IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS WIRE REPAIR IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17332 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure. 6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released.The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17333 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS SYSTEM WIRE SPLICE REPAIR Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. CONNECTOR POSITION ASSURANCE (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. TERMINAL POSITION ASSURANCE (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. Tools Required J-38125 Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17334 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes.Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17335 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J-38125 Terminal Repair Kit IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wires insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17336 - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - if the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17337 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17338 Equivalents - Decimal and Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17339 Equivalents - Decimal and Metric Part 2 Arrows and Symbols ARROWS AND SYMBOLS This service data uses various symbols in order to describe different service operations. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17340 Conversion - English/Metric Part 1 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17341 Conversion - English/Metric Part 2 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. Dealers in the US may contact Dealer Support Materials at 1-800-235-8521 and request Form Number DWS-01 to obtain these worksheets at no cost. Dealers may also access the DWD Store in Dealerworld and search for form DWS-01 or select Service Forms under Other Links and then select Diagnostic Worksheet (under Bulletin Information on use of Diagnostic Worksheet). Please limit your requests to a reasonable quantity. Registered and Non - Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17342 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17343 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17344 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear in this service data. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown that have product numbers beginning with J, SA or BT are available for worldwide distribution from: OE Tool and Equipment Group Kent-Moore 28635 Mound Road Warren, MI, U.S.A 48092-3499 Phone: 1-800-345-2233 or 586-574-2332 Monday through Friday 8:00 am-7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321 The TECH 2 scan tool and accessories can be purchased through: Dealer Equipment and Services 5775 Enterprise Dr. Warren, MI, U.S.A 48092-3463 Phone: 1-800-GM-TOOLS or 586-574-2332 Monday through Friday 8:00 am-6:00 pm EST Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17345 Fax: 1-586-578-7205 Fasteners FASTENERS METRIC FASTENERS This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(R) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(R) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FASTENER STRENGTH IDENTIFICATION Fasterner Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17346 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17347 Metric Prevailing Torque Fastener Minimum Torque Development METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17348 English Prevailing Torque Fastener Minimum Torque Development ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17349 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. - Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17350 Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry. ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17351 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17352 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17353 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17354 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17355 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17356 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17357 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17358 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17359 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17360 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17361 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17362 Power Window Switch: Connector Views Window Switch - Driver (Coupe) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17363 Window Switch - Driver C1 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17364 Window Switch - Driver C2 (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17365 Window Switch - RR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17366 Window Switch - Passenger (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 17367 Window Switch - LR (Sedan) (With RPO Code A31) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front Power Window Switch: Service and Repair Power Window Switch Replacement - Left Front Power Window Switch Replacement - Left Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 17370 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Left Front > Page 17371 Power Window Switch: Service and Repair Power Window Switch Replacement - Right Front Power Window Switch Replacement - Right Front Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise Window Frame: Customer Interest Body - Rear Door Wind Noise Bulletin No.: 05-08-58-004 Date: August 22, 2005 TECHNICAL Subject: Rear Door Wind Noise (Apply Sealer) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment on wind noise coming from the rear door stationary glass. Cause This condition may be caused by the rubber seal surrounding the stationary glass not making contact to the door frame. Correction 1. Remove the rear door stationary door glass following SI Document ID 1549117. 2. Apply 5 mm (1/4 in) bead of 3M(R) Bedding & Glazing Compound around the center of the stationary door glass frame. 3. When reinstalling the stationary glass, there is a metal tang at the top of the division post. Pull the vent glass down and rearward until you hear this metal tang seat into the square hole in the door frame. Refer to the arrow in the illustration above. 4. Reinstall the door trim following SI Document ID 1549117. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise > Page 17380 Parts Information Warranty Information For vehicles repaired under warranty, use table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise Window Frame: All Technical Service Bulletins Body - Rear Door Wind Noise Bulletin No.: 05-08-58-004 Date: August 22, 2005 TECHNICAL Subject: Rear Door Wind Noise (Apply Sealer) Models: 2005 Chevrolet Cobalt 2005 Pontiac Pursuit (Canada Only) Condition Some customers may comment on wind noise coming from the rear door stationary glass. Cause This condition may be caused by the rubber seal surrounding the stationary glass not making contact to the door frame. Correction 1. Remove the rear door stationary door glass following SI Document ID 1549117. 2. Apply 5 mm (1/4 in) bead of 3M(R) Bedding & Glazing Compound around the center of the stationary door glass frame. 3. When reinstalling the stationary glass, there is a metal tang at the top of the division post. Pull the vent glass down and rearward until you hear this metal tang seat into the square hole in the door frame. Refer to the arrow in the illustration above. 4. Reinstall the door trim following SI Document ID 1549117. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 05-08-58-004 > Aug > 05 > Body - Rear Door Wind Noise > Page 17386 Parts Information Warranty Information For vehicles repaired under warranty, use table. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 17401 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Inner Front Side Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Front Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 17402 Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Window Belt Inner Sealing Strip Replacement > Page 17412 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair Window Regulator Handle Replacement - Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Power) Window Regulator Replacement - Front Door (Power) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 17421 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door (Manual) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 17422 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Manual Window Regulator Replacement - Rear Door (Manual) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 17427 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Power Window Regulator Replacement - Rear Door (Power) Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures Windshield Moulding / Trim: Procedures Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 17433 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 17434 Windshield Moulding / Trim: Removal and Replacement Windshield Reveal Molding Replacement Removal Procedure Important: The window reveal molding is an applied molding design that is separate from the window. The reveal molding may be replaced with the window as an assembly, or the reveal molding may be available as a separate part. The window molding can only be replaced by removing the window. The old molding can not be reused. 1. Remove the windshield. 2. Place the window on a clean prepared surface. 3. Remove the molding from the windshield using a razor scraper. Installation Procedure Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 17435 Important: Apply the window reveal moldings in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 2. Using a heat gun, ensure that the temperature of the window and the reveal molding is approximately 29-32°C (85-90°F). 3. Apply masking tape around the window, 8.5 mm (0.33 in) from the window edge (a), as a guide for locating the window reveal molding. 4. Remove the protective liner from the back of the window reveal molding. 5. Position the window reveal molding to the location tape. Press the molding to the mounting surface. 6. Apply equal pressure along the window reveal molding to uniformly bond the molding to the window. 7. Remove the tape from around the window. 8. Install the windshield. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Spray Nozzle > Component Information > Service and Repair Headlamp Washer Spray Nozzle: Service and Repair WASHER NOZZLE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Depress the washer nozzle tabs to disengage the nozzle from the air inlet grille. Remove the nozzle. INSTALLATION PROCEDURE 1. Push the washer nozzles into the air inlet grille panel until the tabs engage with the panel. 2. Install the air inlet grille panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17444 Windshield Wiper/Washer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17445 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch harness connector. 3. Remove the wipers/washer signal switch retaining screws. 4. Remove the wipers/washer signal switch from the steering column. INSTALLATION PROCEDURE 1. Install the wipers/washer signal switch to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the wipers/washer signal switch screws to 2 N.m (17 lb in). 2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 17449 Windshield Wiper/Washer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 17450 Wiper Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch harness connector. 3. Remove the wipers/washer signal switch retaining screws. 4. Remove the wipers/washer signal switch from the steering column. INSTALLATION PROCEDURE 1. Install the wipers/washer signal switch to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the wipers/washer signal switch screws to 2 N.m (17 lb in). 2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair HOSE REPLACEMENT - WINDSHIELD WASHER REMOVAL PROCEDURE 1. Open the hood. 2. Remove the right front fender liner. 3. Disconnect the washer hose from the washer pump. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Disconnect the washer hose from the air inlet grille panel. 6. Pull the washer hose pump end out alongside the right front inner fender and into the engine compartment. 7. Remove the washer hose from the vehicle. INSTALLATION PROCEDURE 1. Position the washer hose to the vehicle. 2. Route the washer hose pump end down alongside the right front inner fender and into the right front inner fender area. 3. Connect the washer hose to the attachments at the air inlet grille panel. 4. Lower the vehicle. 5. Connect the washer hose to the washer pump. 6. Install the right front fender liner. 7. Close the hood. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Fluid Pump Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 17457 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the front fender liner. 3. Disconnect the washer pump electrical connector. 4. Disconnect the washer pump hose. 5. Using a small flat-bladed tool, remove the washer pump from the washer solvent container. 6. Using a small flat-bladed tool, remove the seal from the washer solvent container. INSTALLATION PROCEDURE 1. Position the seal to the washer solvent container, pressing in until fully seated. 2. Position the washer pump to the washer solvent container pressing, in until fully seated. 3. Connect the washer pump electrical connector. 4. Connect the washer pump hose. 5. Install the front fender liner. 6. Fill the washer solvent container with washer solvent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER SOLVENT CONTAINER REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the front fender liner. 3. Disconnect the washer pump hose. 4. Disconnect the washer pump electrical connector. 5. Remove the washer solvent container screws. 6. Remove the washer solvent container from the left frame rail. INSTALLATION PROCEDURE 1. Position the washer solvent container to the left frame rail. 2. Install the washer solvent container screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screw to 10 N.m (89 lb in). 3. Connect the washer pump electrical connector. 4. Connect the washer pump hose. 5. Install the front fender liner. 6. Fill the washer solvent container with washer solvent. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17464 Windshield Wiper/Washer Switch Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 17465 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch harness connector. 3. Remove the wipers/washer signal switch retaining screws. 4. Remove the wipers/washer signal switch from the steering column. INSTALLATION PROCEDURE 1. Install the wipers/washer signal switch to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the wipers/washer signal switch screws to 2 N.m (17 lb in). 2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair WIPER ARM REPLACEMENT TOOLS REQUIRED J 39637 Wiper Arm Removal Tool REMOVAL PROCEDURE 1. Turn the ignition ON. 2. Turn the wiper switch to DELAY. 3. Turn the ignition OFF when the wiper arms are paused at the bottom of the wipe pattern. 4. Remove the wiper arm nut cover. 5. Remove the wiper arm nut. 6. Using J 39637, remove the wiper arm from the wiper pivot stud. INSTALLATION PROCEDURE Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 17469 1. Install the wiper arms onto the wiper transmission. 2. Align the wiper blades to the dots in the lower windshield blackout. 3. Install the wiper arm nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the nut to 25 N.m (18 lb ft). 4. Install the wiper arm nut cover. 5. Operate the windshield wipers and inspect for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 17474 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE 1. Move the wiper arm to the service up position 2. Press the wiper blade clip button in to release the wiper blade from the inside radius of the wiper arm. 3. Remove the wiper blade out through the opening in the wiper arm. INSTALLATION PROCEDURE 1. Install the hook of the wiper arm through the opening in the wiper blade. 2. Press the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 3. Position the wiper blade pivot in the inside radius of the wiper arm hook. 4. Move the wiper arm back to the parked position. 5. Operate the windshield wipers and inspect for proper operation. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17477 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the wiper blade from the wiper arm. IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17478 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations LR of the Engine Compartment Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Windshield Wiper Motor Assembly Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 17484 Wiper Motor: Service and Repair WIPER MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper drive system module. 3. Remove the wiper crank arm nut. Remove the wiper crank arm from the wiper motor. 4. Remove the wiper motor screws. 5. Remove the wiper motor from the wiper drive system module. INSTALLATION PROCEDURE 1. Position the wiper motor to the wiper drive system module. 2. Install the wiper motor screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten the screws to 8 N.m (71 lb in). 3. Install the wiper motor crank arm and crank arm nut. Tighten the screws to 25 N.m (18 lb ft). 4. Install the wiper drive system module. 5. Install the air inlet grille panel. Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Wheel and Column Chevrolet Cobalt Workshop Manual (L4-2.0L SC VIN P (2005)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 17488 Windshield Wiper/Washer Switch